High-performance rare earth magnets in metal injection molding

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Artwork
Innovation
MIMplus Technologies has industrially implemented and patented the production of rare earth magnets using metal injection molding.
Challenge
challenge1 Industry
challenge2 Communication-technology
challenge3 Electro-mobility
challenge4 Robotics
challenge5 Actuators
challenge6 Electronics
challenge7 Sensors
Leading magnet applications require increasingly complex, smaller and more powerful permanent magnet made of rare earths.
Conventional production technologies are not able to meet the future requirements of high-end applications.
Technology
Magnets in metal injection molding
Patented Technology Certificate Logo
MIM-Graphic
The production of rare earth magnets using metal injection molding combines the advan­tages of established manu­facturing processes such as press sintering or polymer injection molding.
complex-icon
Form complexity
For magnets optimally adapted to the application
miniaturisierung-icon
Miniaturization
Smallest magnets with high performance for electronics or medical technology
compress-alt
High power density
Optimized magnets to increase the efficiency of motors and generators
magnet
Application-specific magnetic fields
Field alignment in the injection molding process for variable magnetic field geometries
Case study efficiency
Bildschirmfoto pdf Download icon
Up to
2x
higher energy product compared to isotropic polymer-bonded magnets
Up to
100%
Avoidance of critical heavy rare earths through complex magnet designs
Up to
50%
lower manufacturing costs for Halbach Arrays or comparable magnetic systems
Up to
50%
smaller assemblies through free-form magnets compared to press sintering
Applications
Magnetteil-1
Spiral motor
assembly
Magnetteil-1
Multipole
sensor magnet
Magnetteil-1
Magnet for
loudspeaker
Magnetteil-1
Free-form
magnet
Magnetteil-1
Clip
magnet
The process
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Raw
material
Scrap magnets from various sources as well as new material can be used.
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Powder
production
Hydrogen embrittle-ment produces fine NdFeB powder from the raw material.
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Compounding
Processing step for the production of a feedstock.
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Injection
molding
Injection molding of the base material and alignment of the magnetic field.
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Debinding
The binder is removed in the debinding phase.
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Sintering
Sintering step with subsequent magneti­zation.
Application-specific magnetic fields
Clipmagnet-Magnetfeld
Clip magnet
Halbach-Array-Magnetfeld
Halbach-Array
Wirbelstromoptimierter-Magnet-Magnetfeld
Loss optimized magnet
Our materials
NdFeB

Strongest magnets with highest energy product

Wide range of applications

Production from recycled material possible

CeFeB

Non-critical, readily available raw materials

Good magnetic properties with high remanence

Production from recycled material possible

SmCo

High temperature resistance up to 300 degrees

Very good corrosion resistance

In development

Sustainability
Rare earths are essential, but their mining is associated with serious environmental damages.
Bildschirmfoto Google Earth - Bayan-Obo Mine, China
Recycled magnets vs. magnets made from virgin material
50%
Global warming
45%
Ecotoxicity
48%
Smog
32%
Non carcinogenics
54%
New magnets
Recycling magnets
23rd CIRP Conference on Life Cycle Engineering
The production of new magnets from recycled material significantly improves the environ­mental balance of neodymium magnets.
Case study sustainability
Bildschirmfoto pdf Download icon
Sovereignty of Germany and Europe
Europe's dependency grows as demand increases
dependency
Production of permanent magnets
Carrara et al. 2020
dependency2
Rare earth mining
Adamas Intelligence Research, Rare Earth Elements, Q2 2019

China not only controls the export of rare earth or rare earth magnets, but also the technology needed to mine or process rare earths.

https://www.sciencedirect.com/science/article/ pii/S0959652623004109?via%3Dihub

In the European Union there are actually

200kt*

of Neodym magnets in circulation.

By recycling or reducing the use of rare earths, dependency on China and other rare earths exporting countries can be drastically reduced.

https://www.sciencedirect.com/science/article/ pii/S0959652623004109?via%3Dihub
MIMplus Technologies

MIMplus Technologies specializes in materials technology and inno­vative manufacturing processes.

Thanks to our unique expertise, we can realize complex components and assemblies economically, even in challenging materials.

The German family business is based in Ispringen near Stuttgart.

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Supported by the European Union, awarded the German Raw Material Efficiency Prize. REProMag is Horizon 2020 Success Story.
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