TECHNICAL GUIDE
In today’s industrial landscape, innovation moves fast, and standard off-the-shelf components are often the first obstacle to cutting-edge design. Whether in automotive, aerospace, industrial automation, or advanced medical devices, space, temperature, and performance constraints require unique solutions.
At CIBAS Group, we have made a radical choice: we do not have a catalog of standard products. Every single custom magnet we manufacture starts from a blank sheet of paper.
But how does the process work that transforms an idea into a finished, high-performance, industrialized custom magnetic component?
In this guide, we will analyze every stage of the custom magnet manufacturing process in detail, showing how complete customization is the only truly effective way to optimize your projects.
Many designers make the mistake of adapting their geometric design to the dimensions of magnets available on the market, accepting compromises that negatively affect the efficiency of the final product.
When you work with a specialized partner, the scenario is reversed: the magnet is adapted precisely to the requirements of your project.
This approach offers three immediate competitive advantages:
Because we do not sell off-the-shelf products from a warehouse, our work does not start with an order code, but with a technical call. The co-design phase is where your objectives meet our expertise in magnet technology.
Analysis of Requirements and Design Constraints
The customer provides their technical drawing, and we analyze the four pillars of the magnetic circuit:
Magnetic Simulation
Before starting any production line, we verify theoretical feasibility using advanced simulation software such as COMSOL Multiphysics.
Simulation allows us to map magnetic flux behavior throughout the entire circuit, predict potential saturation zones or demagnetization risks, and calculate the actual forces involved. This step minimizes the risk of error, ensuring that the first physical prototype already meets expectations.
Do you have a magnetic project to develop?
From requirements definition to FEM simulation, our team can help you identify the most suitable solution for your application.
Alloy selection is a decision based on multiple requirements. The four families of magnetic materials we work with are available in dozens of different chemical grades:
Neodymium-Iron-Boron (NdFeB)
The material of choice when maximum magnetic energy density is required within the smallest possible space. We develop special grades, such as the SH, UH, EH, and AH series, capable of withstanding elevated temperatures (up to 200°C–220°C) while reducing irreversible flux losses.
Samarium-Cobalt (SmCo)
Ideal for critical applications in the aerospace, motorsport, and defense sectors. It offers exceptional thermal stability (up to 300°C–350°C) and such high intrinsic corrosion resistance that protective coatings are almost never required.
Alnico (Aluminum-Nickel-Cobalt)
Used in industrial applications where temperatures exceed 500°C or where very high residual induction is required, provided that the magnetic circuit is protected against opposing demagnetizing fields.
Ferrite (Ceramic Magnets)
An optimal solution for high-volume applications where cost is a priority and space is not a stringent constraint. Ferrite offers excellent oxidation resistance and operating temperatures of up to 250°C.
Made-to-drawing magnet manufacturing requires flexible technologies capable of adapting to increasingly varied geometries without the rigid constraints of standardized mass production.
The main process used for rare-earth magnets and ferrites is based on powder metallurgy. Pure metals are melted under vacuum and reduced to fine powders, which are then pressed inside shaped molds. During compression, a powerful magnetic field is applied to orient the particles in the magnetization direction required by the design.
The compact blocks are then placed in high-temperature furnaces under a controlled atmosphere to bond the particles together, determining the final density and crystal structure of the material.
Raw sintered blocks have relatively wide tolerances and rough surfaces and are also brittle. They therefore undergo advanced, highly precise machining processes, including:
When the customer’s design requires very tight tolerances directly from the mold or complex geometries—such as integrated slots or plastic inserts—magnetic powders mixed with polymer binders are used.
This compound can be directly injection molded, enabling the production of ready-to-use components while reducing subsequent machining operations.
A custom magnet must maintain its performance over time within its actual operating environment. Since Neodymium is particularly sensitive to oxidation, the choice of coating is an integral part of the custom design process.
Depending on the final application, we apply targeted surface treatments:
One of the stages that best reflects our identity as custom-product manufacturers is our ability to supply not only the individual bare magnet, but a complete magnetic component.
In many cases, customers do not have the equipment or in-house expertise required to handle and secure industrial magnets. We therefore deliver a finished, engineered product that is ready to be integrated directly into your assembly line.
Only once the component has been fully assembled, sealed, and geometrically verified do we proceed with final magnetization. This is essential for three reasons:
Working exclusively to order and according to customized specifications means that every production batch requires a dedicated, tailor-made quality control protocol.
Validation procedures are based on four main areas of analysis to ensure compliance for both the individual magnet and the complete assembled unit:
If your company is developing an innovative application, do not compromise by trying to adapt your project to a catalog of standard solutions. Choosing custom magnets means having complete control over the performance, efficiency, and reliability of your product.
Our engineering team is ready to support you from the initial feasibility study through to the supply of the industrial production batch. Contact us today.
