Magnetic assemblies have become a core element in achieving high performance, intelligent and precise control. In modern industry and technology, the demand for complex products with integrated magnetic assemblies is steadily growing. However, standardized magnets are often difficult to meet the diverse needs of complex scenarios, so custom magnetic assemblies have emerged. Through tailored designs, materials and processes, we provide our customers with a full range of custom magnetic solutions from basic functions to cutting-edge integration.
Value of Horizon Magnetics Custom Magnetic Assemblies:
Custom magnetic components refer to combining permanent magnets (such as Neodymium magnet, SmCo magnet, etc.) with other functional components of non-magnetic materials (housing, mechanical structure, etc.) to form integrated modules that meet specific performance requirements through a synchronous combination of precise location, assembly method, size, tolerance and field focus. Its core value is:
1. Accurate adaptation: Break the size, shape or magnetic limit of standard magnets to adapt to complex installation environments.
2. Functional integration: Integrate multiple technologies to simplify end product design;
3. Improved reliability: Enhance temperature resistance, corrosion resistance and impact resistance through protective coatings and structural optimization.
4. Cost reduction and efficiency: Reduce customer R&D cycles and optimize supply chain management.
How Horizon Magnetics Realize Custom Magnetic Assemblies:
1. Technical communication: Unlike salespeople who only pursue fast sales without enough technical expertise, our engineering and technical experts engage in and lead the project from the very beginning of the project. Experienced technicians with know-how communicate with customers to gain a detailed understanding of their design concepts and requirements, utilizing our knowledge of magnets and applications, as well as FEA tools to calculate flux densities, torques, and forces. Simulation results are used to avoid design errors, verify the feasibility of concepts, thereby shortening research and development time and costs, optimizing costs, and accelerating the progress of products from concept to market.
2. Engineering: Our engineers immerse themselves in using technology and design to ensure the manufacturability of the custom magnet assemblies. They will consider all necessary factors through the whole process from concept to final product such as application, durability, maintenance and safety.
3. Prototyping: Our Research and Development staff will develop the quality prototypes of custom magnetic systems within the affordable budget cost in time. The prototypes will validate the magnetic performance within your system and manufacturability of the magnetic assemblies on a large scale
4. Manufacturing: Our in-house manufacturing capabilities include rare earth magnet production, extensive in-house machining such as milling, turning, grinding & EDM, overmolding, assembly, multipole magnetizing, etc.
Main Aspects to Consider in Designing Custom Magnetic Assemblies:
1. Magnetic strength: Tailored flux density and pull force.
2. Environmental factors: Temperature resistance, humidity, chemical exposure.
3. Size/shape constraints: Miniaturization or complex geometries.
4. Regulatory compliance: RoHS, REACH, or industry-specific standards.
5. Simulation & prototyping Finite Element Analysis (FEA) for field optimization.
6. Cost vs. performance: Balancing budget with high-performance materials (e.g., SmCo for high temps).
Main Manufacturing Techniques in Producing Customs Magnetic Assemblies:
1. Injection molding/overmolding: Encapsulating magnets in plastic for durability.
2. Machining: Precision shaping of magnet or housing.
3. Adhesive bonding: Securing magnets to substrates.
4. Coating processes: Electroplating or spray coatings for protection.
What Affects Cost of Custom Magnetic Assemblies:
1. Materials: Rare-earth magnets (e.g., NdFeB) are costlier but stronger.
2. Volume: Higher quantities reduce unit costs.
3. Complexity: Multi-component assemblies increase labor/machining time.
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