Midwest Advanced Materials

Manufacturing Process

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CRAFTED WITH PRECISION AND CARE

THE JOURNEY TO EXCELLENCE

The manufacturing of sintered magnets is a meticulous process involving precise machining, surface treatment, rigorous inspection, and secure shipping. Each step is vital to achieving the desired specifications for size, appearance, magnetic properties, and durability. This overview highlights the key stages in the machining and finishing process, from grinding to final packaging for shipment.

Precision Machining

Our advanced techniques ensure magnets are manufactured to exact specifications for size, shape, and performance.

Sustainable Production

We prioritize eco-friendly practices by recycling materials and minimizing waste throughout the manufacturing process.

High-Quality Materials

We use premium rare earth elements, including Neodymium and Samarium-Cobalt, to produce durable, high-performance magnets.

Surface Treatment

State-of-the-art plating and coating methods enhance corrosion resistance and extend the lifespan of our magnets.

Rigorous Testing

Every magnet undergoes comprehensive inspection to guarantee optimal magnetic properties, durability, and reliability.

Global Delivery

With secure packaging and worldwide shipping capabilities, we deliver high-quality magnets to customers around the globe.

Raw Materials Preparation

The process of making a magnet starts with the sourcing and preparation of raw materials. These typically include rare earth elements like neodymium, iron, and boron for permanent magnets, or ferrite for ceramic magnets. The raw materials are:
  • Mined and purified.
  • Mixed in precise ratios to achieve the desired magnetic properties.
  • Melted in high-temperature furnaces to form an alloy, which is then cooled and ground into a fine powder.

Compacting/Pressing

The fine magnetic powder is then shaped through a pressing or compacting process. This can involve:
  • Dry pressing: Applying pressure to the powder without adding any liquids.
  • Wet pressing: Mixing the powder with a liquid binder for enhanced precision. During this stage, magnetic fields may be applied to align the particles, ensuring optimal magnetic performance in the final product.

Sintering

Sintering involves heating the compacted material to a high temperature (just below its melting point) in a controlled atmosphere. This step:
  • Fuses the particles together, creating a solid and dense structure.
  • Eliminates pores or gaps within the material, enhancing its strength and magnetic properties.
 
The sintered product typically exceeds the desired size and requires further refinement.
 

Machining

After sintering, the magnet undergoes machining to achieve its final shape and size. This step includes:
  • Grinding, cutting, or drilling with diamond-coated tools (as magnets are brittle and prone to chipping).
  • Creating precise edges and surfaces according to the application requirements. The machined magnets are then inspected for dimensional accuracy.

Surface Treatment

To prevent corrosion and wear, the magnets are treated with a protective coating or plating. Common methods include:
  • Nickel, zinc, or epoxy coatings for neodymium magnets.
  • Oxide coatings for ferrite magnets. This ensures the magnets are durable and suitable for their intended applications.

Magnetizing

The final step is magnetizing the material, which involves exposing the product to a strong magnetic field to align its internal domains and create a permanent magnetic field. The strength and direction of magnetization depend on the intended use. After magnetizing:
  • The magnets are tested to verify their magnetic properties.
  • They are packaged and prepared for shipment.
 

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