High-performance rare earth magnets in metal injection molding
Innovation
MIMplus Technologies has industrially implemented and patented
the production of rare earth magnets using metal injection
molding.
Challenge
Industry
Communication-technology
Electro-mobility
Robotics
Actuators
Electronics
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
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.
Form complexity
For magnets optimally adapted to the application
Miniaturization
Smallest magnets with high performance for electronics or
medical technology
High power density
Optimized magnets to increase the efficiency of motors and
generators
Application-specific magnetic fields
Field alignment in the injection molding process for variable
magnetic field geometries
Case study efficiency
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
Spiral motor
assembly
Multipole
sensor magnet
Magnet for
loudspeaker
Free-form
magnet
Clip
magnet
The process
Raw
material
Scrap magnets from various sources as well as
new material can be used.
Powder
production
Hydrogen embrittle-ment produces
fine NdFeB powder from the raw material.
Compounding
Processing step for the production of a
feedstock.
Injection
molding
Injection molding of the base material and
alignment of the magnetic field.
Debinding
The binder is removed in the
debinding phase.
Sintering
Sintering step with subsequent
magnetization.
Application-specific magnetic fields
Clip magnet
Halbach-Array
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.
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.