Magnetic shapes are injection-moulded

Kane Magnetics International (KMI) also offers the special facility to injection-mould complex, high-precision, anisotropic, multi-pole components in volume at low cost, in sizes down to 0.5g.

Manufacturing magnetic components and assemblies at plants in the UK, France and USA, Kane Magnetics International (KMI) also offers the special facility to injection-mould complex, high-precision, anisotropic, multi-pole components in volume at low cost - and in miniature sizes as small as 0.5 gramme.

Powerful, anisotropic, permanent magnets are magnetized in a preferred direction to achieve higher magnetic properties in that direction.

Polymer-bonded magnetic compounds contain high loadings of magnetic powder (up to about 60% by volume, 90% by weight) dispersed in a polymer matrix.

Their processing temperature is low enough even to enable the mix of several different magnetic powders together in the polymer binder, to achieve an unprecedented range of properties.

Although the volume of magnetic material is less than in sintered magnets, the magnetic effect may be stronger in practice because products can be tailored, without compromise, to the precise requirements of the application.

Offering greater design freedom and more intricate shapes than other magnets without costly machining, polymer-bonded magnets can, for example, be moulded onto inserts like steel spindles or screws (eliminating assembly work), and pole patterns configured for individual design needs.

All or only part of the component may be magnetized.

It is sometimes advantageous in cost terms to make the whole item out of the magnet material and just magnetize the portion requiring magnetic output.

KMI's injection-moulded magnets are lighter than any metallic or ceramic alternatives; very durable; and not susceptible to breaking and chipping - a problem associated with conventional magnets sintered from 100% metal powder.

In practice, the latest polymer-bonded ferrite and rare-earth magnet technology from KMI is providing solutions to many sensing applications including speed control, motion detection and position sensing.

Diverse uses include a magnet for a central heating timer - designed to rotate continuously at 350 rpm on a stationary steel shaft for 10 years - and a magnet that automatically triggers the inflation of the airbag of your motor car.

The precision tolerances achievable in mass production ensure that these safety-critical components are manufactured in high volume with the rigorous part-to-part consistency essential for automated assembly.

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