CUSTOM ENGINEERING MAGNETS

Why choose custom engineering magnetic solutions?

In industries such as manufacturing, automotive, aerospace and electronics, the performance of magnetic components directly affects product quality and bottom line. As a leading magnet supplier, TOPMAG is committed to designing, manufacturing and customizing high-performance NdFeB magnets and other magnetic solutions for our customers’ unique project needs. With ISO 9001:2015 and IATF 16949 certifications, we provide full support from conception to production to ensure that your application is optimal.

Custom Engineering Magnet Design and Manufacturing

TOPMAG provides high-precision magnetic solutions for industrial applications through its precision magnet customization services. Its customized products, developed based on NdFeB permanent magnet materials, achieve a maximum magnetic energy product of up to 52 MGOe, demonstrating significant performance advantages over traditional ferrite magnets. This material property enables more compact magnetic circuit designs, delivering outstanding performance in applications with stringent space constraints, such as new energy motors and precision sensors.

TOPMAG employs computer numerical control (CNC) machining technology to achieve micron-level precision control. It ensures dimensional tolerances remain within ±0.01 mm. To meet the protective needs of various operating conditions, the technical team has developed diverse surface treatment solutions. The nickel-copper-nickel triple-layer plating system provides long-term corrosion resistance, suitable for high-humidity or marine environments; the epoxy resin coating process enhances chemical corrosion resistance through molecular structure design; and the parylene vacuum coating technology maintains stable dielectric performance under extreme temperature conditions. All these coating solutions have passed the ASTM B117 salt spray test certification, achieving an industrial-grade IP68 protection rating.

TOPMAG’s technical service team adopts a full-lifecycle design approach, engaging in customer requirement analysis from the initial parameter modeling stage. Through finite element analysis (FEA), we predict magnetic field distribution and validate the dynamic stability of magnet assemblies using vibration table testing.

Magnetic circuit design and finite element analysis

Magnetic circuit design, as a critical component of permanent magnet system engineering, directly impacts the energy conversion efficiency and operational stability of magnet assemblies under complex conditions. TOPMAG’s technical team has developed an integrated magnetic circuit optimization technology based on multi-physics field coupling analysis. This technology establishes three-dimensional dynamic magnetic field models to analyze magnetic flux distribution patterns. Employing nonlinear finite element analysis (FEA) technology, combined with a material hysteresis loop database and eddy current loss calculation module, achieves precise prediction of magnetic field intensity distribution at Gaussian spatial resolution. It specifically addresses dynamic compensation for magnetic anisotropy changes under high-temperature environments and magnetic domain rearrangement effects caused by high-frequency vibrations.

Through topology optimization algorithms, researchers iteratively compute magnetic pole configurations, simultaneously optimizing the spatial arrangement of magnets and magnetization direction vectors. This multi-objective optimization strategy reduces system magnetic reluctance to 68% of traditional designs and controls the magnetic leakage coefficient within a 5% threshold, significantly enhancing energy density.

Leveraging the parallel processing capabilities of high-performance computing clusters, TOPMAG has compressed the typical magnetic circuit design cycle to 5-10 working days. This technology system has been successfully applied to the development of precision magnetic systems, including magnetic levitation bearings, nuclear magnetic resonance imaging devices, and high-power wireless charging systems, achieving industry-leading consistency in mass production.

Injection molding and overmolding

TOPMAG has developed a functional overmolding technology in the field of magnet-integrated manufacturing, achieving enhanced interfacial bonding between magnetic components and engineering plastics through molecular chain structure regulation. This process uses polyamide 66 as the structural overmolding base material, with a tensile strength of 80 MPa and a heat deflection temperature exceeding 250°C, combined with an impact-resistant modified layer of thermoplastic elastomer to create a composite protective system with gradient mechanical properties. Based on an intelligent manufacturing system with modular injection molding units, this process achieves an ultra-short molding cycle of 30 seconds per cavity. This large-scale manufacturing capability has been certified under the IATF 16949 automotive quality management system, making it particularly suitable for producing magnetic modules in high-reliability applications such as automotive sensors and industrial encoders.

Assembly and integration

TOPMAG has established a magnet-integrated manufacturing system based on Industry 4.0 standards, enabling high-precision composite assembly of permanent magnet components with electromechanical systems. This system achieves precise assembly of complex components, such as embedding magnets into motor rotors and encoder stators, with millimeter-level positioning accuracy. To meet the high-volume demands of new energy vehicle drive motors, a multi-station synchronous assembly process has been developed, with a single production line outputting an average of 5,000 integrated component sets per day.

The technical team has implemented a full-lifecycle validation system. Assembled components undergo geometric tolerance inspection using coordinate measuring machines. This technology has been applied to the mass production of critical components, such as position sensors for automotive motors and actuators for ADAS systems. Failure Mode and Effects Analysis (FMEA) indicates a Mean Time Between Failures (MTBF) exceeding 15,000 hours.

Packaging and market preparation

TOPMAG sees packaging as a vital part of its product assembly, blending cutting-edge materials with smart design to create solutions that are both practical and visually appealing. We use ultra-strong corrugated cardboard to craft packaging that’s tough, durable, and meets high industry standards. This packaging can easily withstand drops from 1.5 meters, keeping damage rates during shipping below 0.12%. For customers needing small, custom orders, they can handle orders as small as 1,000 units, turning concepts into delivered products in about a week.

Industry application: Magnets are everywhere

Magnetic technology is quietly driving exciting advancements across various industries today. Smart magnetic materials and innovative engineering are playing a crucial role in numerous key sectors.

In the aerospace field, satellites soar through the vast universe, precisely supporting navigation for your phone. Ultra-strong miniature magnets, robust and durable, withstand the extreme conditions of space, from freezing cold to scorching heat, enabling super-precise GPS navigation.

In the automotive sector, super magnets enable motors to operate more smoothly and efficiently. Clever magnetic circuit designs optimize motor performance, significantly extending the range of high-end electric SUVs, eliminating the hassle of frequent charging.

In the 5G field, streaming videos, playing games, and connecting smart homes—5G makes everything lightning-fast! Magnetic components provide high-performance support for 5G base stations, ensuring clear signals even in bustling cities.