From invisible closures in consumer tech to satisfying clicks in luxury packaging, magnets are becoming increasingly useful and important in shaping how users interact with modern products. Subtle, durable, and mechanically elegant, they offer a unique tool for product designers, but only when used with care.
Here are five key things every product designer should understand before integrating magnets into their next design.
1. Magnetic Force Is More Sensitive Than You Think
Magnetic strength is affected by a whole range of factors and it isn’t just about the size or grade of the magnet as one might assume.
Things that can affect magnetic performance:
- Air gaps (even a thin plastic wall or adhesive layer)
- Surface material (steel vs stainless steel vs another magnet)
- Orientation and distance
Top Tip: Always prototype with the actual materials and spacing in your product. Small differences can lead to large performance gaps.
2. Neodymium Magnets Are Powerful – but Also Brittle and Sensitive
Neodymium (NdFeB) magnets are commonly used in product design for their high strength-to-size ratio, but like all materials, they do have limitations:
- They’re brittle and can chip or crack if slammed together.
- They’re temperature-sensitive, losing strength above ~80°C unless specially rated.
- They require protective coatings to avoid corrosion.
Top Tip: Always specify the right grade (e.g., N42, N52) and finish (e.g., nickel, epoxy) for your intended environment.
3. Magnetic Fields Aren’t Directionless – Polarity really Matters
Polarity is often overlooked during concept design. Aligning north to north or south to south results in repulsion, and in multi-magnet systems, incorrect polarity could cause unexpected behaviour and errors, like skewed closures or misaligned modules.
Top Tip: Map polarities early and document them clearly for manufacturers and prototyping teams.
4. Holding Force ≠ Usability
Just because a magnet has a particular listed “pull force”, it doesn’t mean your user can apply it; there’s a difference between direct pull, shear force, and practical usability which is vital to understand for product development. When reviewing magnetic specifications, it’s important to distinguish between different types of force and what they actually mean in a real product.
Direct Pull (Axial Force)
This is the maximum force required to pull a magnet straight away from a flat surface it’s fully contacting (usually measured under ideal lab conditions). It’s the headline figure often listed in data sheets. Example: Lifting a magnet directly off a steel plate.
Shear Force
This measures a magnet’s resistance to sliding along a surface, rather than being pulled away. Shear forces are typically much lower than direct pull forces. Example: A cabinet door held by a magnet that can be slid sideways to open.
Practical Usability
This is where design context, user interaction, and real materials come in. The force a user can apply, the grip they have, the angle of motion, and the presence of covers or adhesives all influence how strong the magnet feels. A magnet with a 5kg pull rating might feel secure—or frustratingly strong—depending on the product’s design.
🔍 Tip: Design for real user interaction, not just raw specs, and prototype for real-world use cases. The interaction between materials, motion, and ergonomics will determine how effective and satisfying the magnet is in your product.
5. Magnets Add Simplicity, But Require Precision
One of the biggest benefits of magnets is their ability to reduce complexity: no springs, latches, or hinges. But that elegance only works if tolerances, placement, and shielding are dialled in. Some issues resulting from overlooking specifics include:
- Misalignment can cause rattling or wear.
- Improper containment can cause magnetic interference with electronics.
- Over time, mechanical slippage can shift magnet positions.
Top Tip: Treat magnets as integral engineered components, rather than afterthoughts. Test for repeatability, durability, and magnetic interference if your product contains sensitive elements.
Magnets are a powerful design tool, both literally and creatively. But great magnetic experiences don’t happen by accident; they’re the result of thoughtful engineering, realistic prototyping, and attention to both physics and user behaviour.
At Magnet Expert, we support designers and engineers with precision magnets, custom assemblies, and the technical guidance to help your ideas click into place, beautifully and reliably.
Got a concept in mind? Talk to our team about how to integrate magnets into your product design the right way.
