Injection molding uses a solid binder (e.g. a plastic or thermosetting epoxy) plus the?magnetic material?but gives a greater variety of shapes and complexity of shapes compared to compression bonded. Isotropic meterials– the magnetized coil fixture design determines the magnetic material it takes.

Overmolding magnet is possible with injection molding process.

Injection molded magnets are produced in tens or hundreds of thousands of magnets per production run.

Advantages:

  • More complex shapes are possible
  • Overmold, insert mold, etc all possible
  • NdFeB, SmCo, Alnico and Ferrite magnetic material possible
  • Hybrid versions as well (e.g. Ferrite+NdFeB) with combined properties
  • Low electrical conductivity, low eddy currents
  • Good tolerances. More resistant to chipping than compression bonded

Disadvantages:

  • Injection molded magnets offer lower magnetic performance than the compression bonded magnets (due to lower magnetic loading)
  • Possible tooling charges for production and magnetizing

Applications of Injection Molded Magnet

  • Motors
  • Sensors
  • Injection molded rotor assemblies
  • Insert molded magnetic components
  • Overmolding magnetic components
  • Medical pump magnet