Injection Molded Magnets Manufacturer

Injection Molded Magnets

Injection-molded magnets are not your typical magnets. They are quite advanced thanks to the addition of a polymer binder, which makes them relatively denser and more powerful. This unique magnet manufacturing process also elevates their tolerance to high temperatures and corrosive materials.

Features of Injection Molded Magnets

Pros & Cons of Injection Molded Magnets
Injection Molded Magnets Materials

Injection molded magnets feature distinct, first grade components, which are compounded using an elaborate process. This results in first-rate magnets distinguished by elevated features, which are highly sought after in varying applications. Some of the primary features that have made them a household name include;

· High Tolerance

These magnets have high-quality magnetic powders as their foundation block. They are also supplemented by polymer binders renowned for their rigidity. This results in the creation of magnets with a robust configuration capable of resisting numerous rough conditions and elements. These include high temperatures and corrosive elements.

· High Strength

Traditionally, these magnets are manufactured from highly reputable materials, which range from rare earth minerals to ceramic. The high magnetic strength of these natural ferromagnetic materials is transferred into the final product. This gives you powerful magnets capable of delivering high magnetic forces and withstanding considerable impacts.

· Complex Shape

The shape of your magnet greatly impacts its performance and magnetic capabilities. Thankfully injection molding permits the production of intricate magnets distinguished by complex designs. Your injection molded magnet could be designed to feature holes, thin walls, or even undercuts. This complexity in shape allows you to exploit injection-molded magnets in sophisticated applications such as magnetic levitation.

· Corrosion Resistance

These magnets feature high-grade polymer binders such as polyphenylene sulfide which elevates their resistance to corrosion. As such, you can deploy injection molded magnets in settings exposed to moisture or acidic components that can cause rusting. Furthermore, most of the ferromagnetic materials that form the foundation of these magnets are relatively corrosion-resistant.

· Magnetic Orientation

Injection molded magnets are perfectly designed and they may come in intricate designs, which endow them with improved magnetic capabilities. Their alignment not only elevates their magnetic strength, it also improves their resistance to corrosion and extreme temperatures.

· Overmolding

Injection molded magnets that utilize plastic polymer binders are typically overmolded and this gives them a superior quality. This allows manufacturers to produce them in fewer and simpler processes whilst elevating their quality. Furthermore, over-molding improves the tolerance levels of your magnets.

Types of Injection Molded Magnets

Ferrite Injection Molded Magnets
Ferrite Injection Molded Magnets

These magnets consist of iron oxide and barium carbonate bonded using a robust polymer binder. This composition equips them with superior coercivity at a comparatively lower fee. They are greatly revered as magnetic solutions for audio speakers, toys, and motors.

Nylon 6 Injection Molded Magnets
Nylon 6 Injection Molded Magnets

These are injection molded magnets that incorporate nylon polymer binders. They are renowned and revered for their immense magnetic strength as well as their tight tolerance. With a nylon injection molded magnet, you do not have to worry about corrosion meaning you can deploy them in applications or settings exposed to chemicals or moisture.

Polyphenylene Sulfide Injection Molded Magnets
Polyphenylene Sulfide Injection Molded Magnets

These magnets are universally admired courtesy of their chemical and extreme temperature tolerance. However, these impressive qualities mean that procuring one will need you to dig deeper into your pockets.

Nylon 12 Injection Molded Magnets
Nylon 12 Injection Molded Magnets

These are improved grades of nylon 6 injection molded magnets. As such they boast of a superior impact tolerance and better flexibility. However, they command a relatively higher fee due to the high price tag placed on nylon 12 polymer binders. This relatively higher cost is however offset by their impressive rewards which include high-temperature resistance.

Rare Earth Injection Molded Magnets
Rare Earth Injection Molded Magnets

Rare earth injection molded magnets are the most prominent sub-category and they are greatly revered for their strength and durability. They are referred to as rare earth magnets because they utilize rare earth materials as their foundation stone.  These injection molded magnets include;

Why You Should Opt for Injection Molded Magnets

Injection-molded magnets have grown to become one of the most admired magnet solutions in existence thanks to their multiple benefits. If you switch to an injection molded magnet, expect to reap the following fruits;

  • Undeviating Quality: The intricate manufacturing process exploited to craft these magnets guarantee high-quality in every piece manufactured. These magnets come with precise dimensions thereby ensuring that their magnetic properties are consistent.
  • Heightened Strength: These magnets are pretty thick and this elevates their vigor and magnetic strength. They can withstand considerable impact and their reliance on strong magnetic materials endows them with robust magnetic properties.
  • Value for Money: They exploit naturally available materials, which are relatively cheaper to acquire. Furthermore, the injection molding technique is quite efficient making them quite affordable. Additionally, this manufacturing process results in reduced material wastage thereby saving you money.
  • Corrosion Resistance: Most injection molded magnets are manufactured using corrosive-resistant ferromagnetic materials. Adding a layer of a polymer binder elevates their resistance to corrosion since the utilized binders are rustproof.
  • Multi-Functionality: One of the primary reasons responsible for the tremendous prominence of injection molded magnets is their ability to accomplish numerous magnetic operations. You can exploit them in magnetic separation, levitation, and lifting among others.

How to Make Injection Molded Magnets

For injection molded magnets to be produced, varying intricate steps are undertaken. This ensures that you get quite powerful magnets with outstanding properties. Here is a step-by-step breakdown of their manufacturing process.

Material Selection: First, the materials that will act as the foundation of your injection molded magnets are chosen and assembled. When choosing the materials ensure you go for a magnetic powder endowed with likeable features since these features will be translated into your final magnet.

Raw Material Compounding: Once you have settled on specific binders and magnet powders, proceed to mix them. While undertaking this step, pay special attention to the portions as this can positively or negatively influence your magnet’s quality.

Heating: Consequently, the resulting mixture of raw materials is injected into a furnace, where it is heated at high temperatures. This is referred to as the injection molding process. Make certain you conform to the molding instructions applicable to your material type.

Molding: The heated material is then dispensed into a uniquely designed mold, which gives it its final shape. This process also determines the size of your final magnet.

Magnetization: This process is engineered to equip your injection molded magnets with magnetic capabilities. You can accomplish this using numerous techniques but the most commonly used method involves exposing them to foreign magnetic fields.

Cooling: Finally, the magnetized component is subjected to a cooling agent such as cold water. This does not only cool them but it also makes them firmly solid.

Surface Treatment: This is an optional process that involves adding a coat to your magnets. These coats utilize varying materials and are designed to improve features such as corrosion resistance and temperature tolerance.

Quality Assurance: Finally, the manufactured magnets are assessed and tested to ensure they meet the stipulated demands. Some of the main tests carried out include examining their magnetic strength and curie temperature.

Common Uses of Injection Molded Magnets

Thanks to their unique manufacturing process, injection molded magnets demonstrate unique yet impressive qualities. This has made them a household magnetic solution for a plethora of distinct applications, which include;

  • Electric motors.
  • Audio speakers.
  • Magnetic sensors.
  • Toys.
  • Refrigerator door seals.
  • Phone holders.
  • Magnetic boards.
  • Jewelry clasps.
  • Medical devices.
  • Magnetic storage devices.
  • Magnetic door catches.
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