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BESPOKE MAGNET DESIGN - CONSIDERATIONS, SPECIFICATIONS & LIMITATIONS

At Magnet Expert Ltd we specialise in manufacturing custom, made-to-order magnets. If you can’t find the right magnet from our stock range of over 400 shapes and sizes, then our experts will work with you to understand the fine details of your application before providing advice regarding the design and specifications of the most effective magnetic assembly, bespoke for your application.

Our advanced, custom-manufacturing facilities enable us to work with all permanent magnet materials and grades to create bespoke magnets and assemblies as unique as your application. We are able to manufacture custom magnets in sample quantities and high-volume production runs. Typically custom magnets will be manufactured and dispatched within five weeks.

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Designing a custom-made magnet

To turn your ideas into a finished magnetic product, our production team will require a sketch or technical drawing. But even before this stage is reached our team are always on hand to provide specialist advice. To turn your ideas into a finished magnetic product, our engineers will require the following information:

  • Shape
  • Size, including tolerances
  • Material and grade
  • Desired coating
  • Direction of magnetism, e.g. which faces the poles will be located
  • Desired physical pull strength
  • Maximum operating temperature, if applicable
  • Quantity

Considerations

There are many factors to consider when designing a permanent magnet or magnetic assembly for a new application, which can be rather daunting if you have not previously worked with magnets. Thankfully we are the magnet experts, so you don’t have to be. When designing a custom-magnet, the following considerations need to be taken into account.

 

What is the primary function of the magnet?

Permanent magnets are typically used for one of seven reasons; to hold, move, clamp, filter, activate a sensor, generate current or to create a dampening effect. Before designing a magnet, first it is important to understand exactly how it will be used.

 

Will the magnets be subjected to physical stress?

All magnetic material is typically brittle. Toprotect against constant impact or sudden shock, magnets can be coated, or placed inside a steel shell.

 

Will the magnets be subjected to temperature extremes?

Different materials and grades of magnets have very different maximum operating temperatures and temperature coefficients. For example standard grade neodymium magnets will suffere irreversible losses in performance at 80 degrees Celsius, whereas alnico magnets can withstand temperatures of up to 500 degrees Celsius before suffering irreversible losses.

 

Will the magnets be used in a corrosive environment?

Some permanent magnets, such as neodymium magnets are highly susceptible to corrosion, whereas ferrite magnets will never corrode. Susceptible magnets can be finished in a wide range of different coatings to increase their resistance to corrosion.

 

Does the magnet require a specific field strength?

Field strength is one value which contributes towards the overall magnetic performance of a magnet. Some applications such as sensor activation require a magnet with a specific field strength or open circuit flux density, measured in Gauss.

 

Will the magnet be working through an air gap?

A magnet does not always need to be in direct contact with the surface or component it is interacting with and some magnetic materials will provide a greater depth of field than others. At Magnet Expert we test all our stock magnets through a variety of air gaps.

 

How will the magnet be fixed in place?

Although often simple in terms of solution, the fixing method is a vital consideration. As magnetic material is brittle is impossible to thread a naked magnet, which is why adhesive is often used. If a fixing thread is required, this can be added to a steel shell encasing the magnet.