Digital Twin Technology in Magnet FactoriesHow Magnetic Toys Are Made

Digital Twin Technology in Magnet FactoriesHow Magnetic Toys Are Made

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After the material is pressed into shape, it undergoes a process called sintering. Sintering involves heating the shaped material in a furnace at very high temperatures without melting it. This process bonds the particles together, making the magnet dense and solid. The temperature and duration of sintering vary depending on the type of magnetic material used. For instance, neodymium magnets require a highly controlled environment because they are sensitive to oxidation and can lose their magnetic properties if exposed to air at high temperatures. Therefore, manufacturers often carry out sintering in a vacuum or inert gas environment.

Once sintering is complete, the magnets are cooled and then cut or ground into the final required dimensions. This stage often involves using diamond-coated tools since magnets, especially sintered ones, are hard and brittle. Precision is essential, especially when the magnets are used in industries such as aerospace, defense, and medicine where exact specifications are critical. The finished magnets may then be coated or plated with materials such as nickel, zinc, or epoxy to protect them from corrosion and mechanical wear. Without proper coating, neodymium magnets, in particular, are highly vulnerable to rust and degradation.

Magnetization is the next crucial step in the manufacturing process. After shaping and coating, the  Lift Magnets magnet must be exposed to a very strong magnetic field to align the magnetic domains permanently. This is usually done using a magnetizing coil or pulse magnetizer. The strength and direction of this field determine the final polarity and power of the magnet. After magnetization, the magnet is tested for quality assurance. Quality testing may include checking magnetic strength, measuring the direction of magnetism, inspecting physical dimensions, and evaluating resistance to temperature and corrosion. High-end manufacturers often use automated equipment and computer-aided systems to ensure that every magnet meets strict industry standards.

Custom magnet manufacturing is a growing trend in today’s world. As industries demand more specialized applications, manufacturers are innovating with new materials, shapes, and magnetic properties. Magnets can be made in various shapes including discs, blocks, rings, cylinders, and even complex 3D geometries. Some applications require magnets with multipole configurations, meaning they have multiple north and south poles on the same surface. These require advanced tooling and magnetization processes. For example, magnetic encoders and rotary sensors often use such configurations to detect rotation or movement with high precision.