Custom Molded Magnets

Phoenix America is a U.S. manufacturer of custom molded magnets engineered to your exact specifications. Our injection molded magnets are produced by blending magnetic powder with a polymer binder, enabling complex geometries, tight tolerances, and integrated assemblies that sintered magnets cannot achieve.

The low processing temperatures used in injection molding allow a wide variety of magnetic powders to be incorporated into a polymer binder, alone or in combination. The result is an unprecedented range of magnetic properties in a single, net-shape part with no secondary machining required.

Shapes and Design Flexibility

Custom molded magnets can be produced in virtually any shape, from simple cylinders and arcs to complex gears, spheres, flow propellers, and multi-pole rings. All or only part of the molded device can be magnetized, making it cost-effective to mold an entire part from magnetic material and magnetize only the section requiring magnetic output.

Insert Injection Molding

Magnet material can be molded directly into, onto, or against other assembly components, eliminating downstream assembly steps. This process is known as insert injection molding. Phoenix America can overmold magnetic material onto metal shafts, housings, or rotor cores, consolidating multiple parts into a single integrated assembly and reducing overall production costs.

Materials

Phoenix America offers injection molded magnets in a range of magnetic powders and polymer binders to meet your application and environmental requirements.

Magnetic Powders:

Ferrite - Cost-effective and corrosion-resistant, with multiple alloy grades available
Neodymium Iron Boron (NdFeB) - High-performance rare earth material with a range of energy products and coercivity levels
Hybrid Formulations - Custom powder combinations developed by Phoenix America for specific application demands

Polymer Binders: Nylon 6, Nylon 11, Nylon 12, and PPS (Polyphenylene Sulfide). Binder selection impacts strength, maximum use temperature, corrosion resistance, and dimensional stability.

Temperature Characteristics

Maximum use temperature is a function of both the magnetic alloy powder and binder selected. Ferrite powders in Nylon 6 have tested satisfactorily at 150°C, while ferrite in PPS performs reliably up to 180°C. Nylon 12 melts above 170°C and is not recommended for use above 150°C regardless of powder selection. The highest energy NdFeB grade, with an intrinsic coercivity of 9,500 Oersteds (760 kA/m), suffers significant irreversible magnetic loss above 120°C regardless of which binder is used.

Full specifications and maximum use temperatures are listed on each product's individual data sheet.

Tolerances

Injection molded magnets conform dimensionally to the precisely-machined mold cavity, delivering close tolerances directly from the tool. Typical tolerance is +/-0.003 in/in, with tighter tolerances on critical dimensions available by negotiation.

Applications

Phoenix America's custom molded magnets are trusted across a wide range of industries and applications. The ability to produce complex geometries, integrate inserts, and tailor magnetic properties makes injection molded magnets the preferred choice for engineers across multiple sectors.

Automotive

Injection molded magnets are widely used in automotive sensing and motor applications, including ABS sensors, speed sensors, throttle position sensors, crankshaft and camshaft position sensors, and brushless DC motor rotors. The ability to mold directly onto shafts and housings makes them ideal for high-volume automotive assembly.

Industrial

Flow meters, encoders, pumps, compressors, and industrial motors all benefit from the design flexibility and dimensional consistency of custom molded magnets. Complex rotor geometries that would be impossible to achieve with sintered magnets can be molded as a single net-shape part.

Medical Devices

Custom molded magnets are used in drug delivery systems, surgical tools, and diagnostic equipment where precise magnetic output, biocompatibility, and dimensional accuracy are critical requirements.

Consumer Electronics

DC motors, actuators, hard drives, and small appliance motors rely on injection molded magnets for consistent performance in compact, high-tolerance designs.

HVAC

Blower motors, fan assemblies, and variable speed drives utilize custom molded magnets for their ability to achieve multi-pole configurations and integrate directly into motor housings.

Aerospace and Defense

Precision actuators, guidance system components, and sensing applications demand the tight tolerances and reliable magnetic performance that Phoenix America's injection molded magnets consistently deliver.

Frequently Asked Questions

Injection molded magnets use a thermoplastic binder and a standard injection molding process, enabling complex geometries and insert molding. Compression molded magnets use a thermoset binder under high pressure, typically yielding higher magnetic output but limited to simpler shapes.

Yes. Our insert injection molding process overmolds magnetic material directly onto shafts, housings, or other substrates, creating fully integrated assemblies in a single step.

Typical tolerances are +/-0.003 in/in. Tighter tolerances on critical dimensions can be negotiated based on part geometry and material.

We offer injection molded ferrite, injection molded NdFeB (neodymium iron boron), and custom hybrid powder formulations in multiple binder systems including Nylon 6, Nylon 11, Nylon 12, and PPS (Polyphenylene Sulfide).

Yes. Phoenix America supports both prototype development and full high-volume production. Contact our engineering team to discuss your volume requirements, tolerances, and lead times.