Engineering Partnership in Practice
Representative projects across our four product families. Customer names are withheld to respect confidentiality — full references and validation documents are available under NDA.
High-Temperature Rotor Magnet Assembly
Customer
US-based supplier to an EV drive-unit program (customer anonymized).
Challenge
The rotor magnets had to hold performance at 180 °C continuous with eddy-current losses under control, and the assembly had to meet a tight concentricity spec so it could drop straight into the customer's automated line.
Solution
N38UH grade segments with a segmented-gluing layup to cut eddy losses; magnet-to-sleeve assembly done in-house with dynamic balancing; 100 % flux and dimensional check on every assembly before shipment.
Key Facts
- Material / Grade: NdFeB N38UH (high-temperature grade)
- Process: Segmented-glued segments, in-house magnet-to-sleeve assembly, dynamic balancing
- Key Requirement: 180 °C continuous operation, tight concentricity for automated drop-in
- Verification: 100 % flux and dimensional check on every assembly
Validation
FAI with full CMM + magnetic property data, PPAP documentation package, per-lot flux mapping.
Families Involved
Magnet Assemblies · Permanent Magnets
Discuss a Similar ProjectSoft Magnetic Cores for High-Frequency Converters
Customer
European inverter manufacturer (anonymous).
Challenge
Inconsistent core losses between supplier lots were causing efficiency spread in a solar inverter line; the customer needed tighter permeability tolerance and traceable material data.
Solution
Soft magnetic powder cores produced with controlled composition windows and pressed under a locked process recipe; permeability sorted to a tight band; every lot ships with a CoA containing measured core-loss data.
Key Facts
- Material / Grade: Soft magnetic powder core, controlled composition window
- Process: Pressing under locked process recipe, permeability-sorted to a tight band
- Key Requirement: Tighter permeability tolerance and traceable core-loss data
- Verification: Per-lot CoA with measured core-loss and permeability figures
Validation
Per-lot CoA with core-loss and permeability figures; customer's incoming-inspection yield improved after switching, per their QA feedback.
Families Involved
Soft Magnetic Materials · Magnetic Powder
Discuss a Similar ProjectDie-Cast Aluminum Housings for Controller Units
Customer
Electronics OEM, industrial controller product line (anonymous).
Challenge
Two separate suppliers (casting + machining) meant double freight, misaligned tolerance chains and slow root-cause loops when a leak or interface issue appeared.
Solution
A380 die casting, CNC finishing of sealing and mounting interfaces, and anodizing consolidated under one quality system; CMM report on all critical dimensions each lot.
Key Facts
- Material / Grade: A380 aluminum
- Process: Die casting + CNC finishing + anodizing under one quality system
- Key Requirement: Aligned tolerance chain, leak-free sealing and mounting interfaces
- Verification: CMM on all critical dimensions per lot; leak test per lot
Validation
Leak test per lot; PPAP approved on first submission; the housing shipped in the same container as the magnets from the same order.
Families Involved
Metal Components · CNC Machining
Discuss a Similar ProjectMagnetic Couplings for Hermetic Pump Drives
Customer
Pump manufacturer serving chemical processing (anonymous).
Challenge
The coupling had to transfer torque across a sealed isolation shell for aggressive media, with zero leakage over the service life — and survive repeated thermal cycling.
Solution
SmCo inner rotor elements selected for temperature stability and corrosion resistance; magnet-steel coupling assemblies built and magnetized in-house; torque and pull-out testing on every production batch.
Key Facts
- Material / Grade: SmCo (temperature-stable, corrosion-resistant)
- Process: In-house magnet-steel coupling build and magnetization
- Key Requirement: Torque transfer across sealed isolation shell, thermal-cycling endurance
- Verification: Torque and pull-out testing on every production batch
Validation
Torque-curve verification per batch; thermal-cycle sample testing; full material traceability.
Families Involved
Magnetic Couplings · SmCo Magnets
Discuss a Similar ProjectHalbach Array for a Position-Sensing Platform
Customer
Industrial sensor developer (anonymous).
Challenge
The sensor needed a strong, uniform one-sided field from a compact ring — a conventional magnet ring wasted half its flux on the wrong side.
Solution
Cylindrical Halbach array engineered to the customer's air-gap and uniformity targets; segments bonded and magnetized as one piece; field mapping report shipped with each lot.
Key Facts
- Material / Grade: NdFeB (grade selected per air-gap target)
- Process: Segments bonded and magnetized as one piece
- Key Requirement: Strong, uniform one-sided field from a compact ring
- Verification: Helmholtz-coil and field-map verification per lot
Validation
Helmholtz-coil and field-map verification per lot; uniformity within the agreed window on first articles.
Families Involved
Halbach Arrays · Permanent Magnets
Discuss a Similar ProjectFerrite Magnet Arcs for a Cost-Driven Motor Program
Customer
Automotive Tier-2 motor supplier (anonymous).
Challenge
A wiper/blower motor program had a hard cost target that rare-earth magnets would blow through, without giving up flux performance.
Solution
Y30BH-class ferrite arcs with optimized arc geometry to recover flux; DFM review suggested a chamfer change that cut chipping rejects; magnetized assemblies shipped ready-to-press into the rotor.
Key Facts
- Material / Grade: Y30BH-class ferrite
- Process: Optimized arc geometry, chamfer change from DFM review, magnetized ready-to-press
- Key Requirement: Hard cost target without giving up flux performance
- Verification: Per-lot magnetic property certificate (Br, HcB, HcJ, BHmax)
Validation
Per-lot magnetic property certificate (Br, HcB, HcJ, BHmax); PPAP documentation for the annual requalification.
Families Involved
Ferrite Magnets · Rotor Assemblies
Discuss a Similar ProjectNote on data: These cases describe the engineering approach of representative projects. Detailed performance figures, volumes and customer references are shared privately under NDA — contact our team for a conversation relevant to your application.
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