Magnet production
Series production
of customer-specific permanent magnets
Magnet production: series manufacturing of customized plastic-bonded permanent magnets
As a world-leading magnet manufacturer, Max Baermann produces more than 300 million magnets per year in three-shift operation. Our particular expertise lies in plastic-bonded permanent magnets, which are specifically adapted to the requirements of technical applications in the automotive industry, robotics and other sectors.
Our customers value us for consistently high product quality, reliable delivery performance and economical series processes. This is based on around 100 years of experience, modern production facilities, strict quality management, continuous product validation and an international network of sites in Germany, China and the USA.
In magnet production we can process a variety of material combinations into components with complex geometries and demanding property profiles. The following manufacturing processes are available – if required even with custom-built machinery and tooling:
- Injection molding of complex magnetic components
- Calendering of thin magnetic sheets and other flexible magnets
- Extrusion of magnetic strips and profiles
- Pressing of dimensionally accurate molded magnet parts
- Sintering of high-performance magnet elements
Injection molding: series production of complex magnetic components
In injection molding, magnetically filled compound pellets are heated and injected into a mold cavity under pressure. Shaping and function integration take place in a single step, creating precise, repeatable series components that are ready to use without additional finishing. The process is particularly suitable for complex 3D geometries, tight tolerances and integrated features such as ribs, threads or carrier structures. Insert molding is also possible, for example to create a firm connection with shafts or hubs. For you this means less assembly effort, fewer process steps and an economical solution for high volumes.
Calendering: series production of flexible magnetic sheets
In calendering, a magnet-polymer mixture is rolled between rollers into thin sheets. The process runs continuously and produces uniform, sheet-like magnet solutions of reproducible quality. This gives you flexible magnetic materials that are ideal for large areas, continuous sheets or custom cut formats – for example for printable sheets, labels, banners or seals. The material is easy to process further and can be cut, punched or glued without difficulty.
Instead of individual components, you receive continuous sheets that can be converted flexibly and efficiently.
Extrusion: series production of magnetic strips and profiles
In extrusion, the magnetic mixture is forced through a die and formed into a virtually endless strip or profile. For you this means magnet solutions that can be integrated directly into systems, for example as long strips or profiles with defined geometries such as grooves or guides. Additional geometric features are created within the process itself, which significantly reduces assembly and machining effort.
Pressing: series production of economical molded magnet parts
In pressing, a magnetic mixture is compacted into solid molded parts under high pressure and temperature. With plastic-bonded hot pressed magnets, bonding takes place via the polymer – with no additional sintering. Using this process we produce robust, dimensionally accurate components for applications in which simple geometries and reliable properties are the priority. The process is particularly suitable for economical series production with stable, reproducible results.
Sintering: production of high-performance neodymium magnets
n sintering, fine neodymium-iron-boron magnet powder is first compacted under high pressure into a shaped body known as a green compact and then bonded into a solid magnetic material at high temperature. Aligning the magnetic particles during pressing makes it possible to achieve particularly high magnetic performance values. After sintering, the magnets are machined as required by their geometry, coated and finally magnetized.
The process is particularly suitable for high-performance permanent magnets with high energy density where high magnetic performance is required in limited installation space. Sintered NdFeB magnets are therefore frequently used in demanding sensor, actuator and drive applications and enable reliable series production with reproducible magnetic properties.
Our permanent magnets at a glance
Further services and expertise for the development and production of your magnets
At Max Baermann we do not just handle the production of your magnets; we support you comprehensively from the initial product concept through to final series production. In consultation with your specialist departments, we are happy to develop application-specific material combinations and magnet solutions whose engineering and production we continuously monitor and validate for you. Find out more here about the possibilities of working with Max Baermann:
Engineering
We develop materials, compounds and magnets tailored precisely to your application and verify their suitability for series production using simulations and prototypes.
Product and process validation
Our specialists validate process sequences and product properties in every phase of product development to ensure reliable results.
Quality management
Through regular checks, our quality management ensures consistently high quality of our products and services.
Compound production
Based on individual compound formulations, Max Baermann produces high-quality compound pellets from which multifunctional components are made.
Tooling and measurement technology
Max Baermann develops individual tooling and measurement systems that enable us to manufacture your products reliably and efficiently.
