> The Process of Rare Earth Magnets Production
The unparalleled strength of neodymium magnets is only possible due to a sophisticated and delicate atomic particle arrangement and electron spin. The process to produce these technological marvels is no less sophisticated or delicate.
The manufacturing process for rare earth magnets in general and neodymium magnets, in particular, is strictly licensed. Recently some of the most restrictive patents have begun to expire, which has helped spur the market's growth and neodymium magnets' availability.
Even though they are called "rare earth" or "neodymium" magnets, they contain a lot of iron and other metals. All of the neodymium, iron, samarium, cobalt, nickel, etc., come from the ground.
Grinding and Mixing the Alloy
Once the raw material is available, it must be ground to a powder and mixed to create various materials. Different mixtures will create materials with various magnetic properties. Some are stronger, others more durable, and others can last longer in high temperatures.
The next step is to press the mixture together into a structure.
We use a large electromagnet to optimize the pressed mixture for magnetization.
Once the particles are aligned, we can sinter the material to lock everything in place firmly.
Milling and Cutting
The material can be further refined by cutting and machining it into smaller pieces. Tolerances are usually +/- 0.05mm. Micromachining specialists can work with much higher tolerances.
Plating / Coating
After the magnet's final shape is finished, we must coat or plate each piece to protect it from corrosion. This is especially true for Neodymium Iron Boron magnets, which are very susceptible to corrosion. Normal platings include Nickel, Nickle + Copper + Nickel, Epoxy Coating, Gold, ABS Plastic, and Zinc.
Magnetization happens after all of the machining and plating. Neodymium magnets can only be magnetized in the direction they were set up for in the alignment phase.
Each magnet is inspected and tested for quality assurance tests.