Neodymium magnets disk fit tool first, then the geometry-specific sourcing decision report.
This route is tuned for buyers using the neodymium magnets disk query for round-disc NdFeB parts. Start with the tool for fast fit classification, then use the report layer to validate thin-disk geometry limits, the coating-release stack, and RFQ-ready fallback actions before supplier award.
1) Neodymium magnets disk fit tool (primary interaction layer)
Input duty conditions and sourcing constraints for neodymium magnets disk programs. The tool returns fit classification, route recommendation, disk-only release guidance, and immediate next actions.
Prefilled to match the disk reference baseline
The default run mirrors this route's sample case: 16 x 3 mm axial disk magnets, humid duty, standard geometry, and a balanced cost target. Change only the fields that differ in your actual RFQ path.
No result yet
Run the tool to generate fit classification, grade window, and RFQ action path.
The output includes suitability boundaries and a fallback route when NdFeB is not a safe primary lane.
Reference run for neodymium magnets disk: encoder rotor program using 16 mm x 3 mm disk magnets in a humid plant with periodic cleaning cycles.
- Target flux density: 810 mT
- Max operating temp: 106C
- Peak temp: 129C
- Corrosion exposure: Humid with occasional splash
- Shape complexity: Standard disk geometry; thinner 2 mm follow-on variants should be revalidated separately.
- Compliance lane: Industrial with lot traceability requirement
Observed output: Typical output is "Conditional fit": disk-magnet lane remains feasible, but release is gated by thin-disk edge handling controls, ISO 2361 lot-thickness checks, ISO 1463 local edge sections, ASTM B571 adhesion criteria, and one SH fallback lane for thermal margin.
Why this matters: Disk magnets can pass force targets while still failing on thin-geometry, edge-damage, and coating-release controls. This run keeps those risks visible before supplier award.
2) Report summary (decision-ready conclusions)
These cards summarize the key decisions, core numbers, and applicability boundaries so teams can align quickly.
Run tool
Confidence is calculated after thermal/corrosion/shape penalties.
Pending result
Adjusted value includes environment, geometry, and compliance penalties before class mapping.
Pending result
Uses max(adjusted peak, adjusted operating + 8C) so sustained-duty risk is not hidden by transient-only checks.
28-53 MGOe
Source: [S11] plus supplier datasets; usable output still depends on load-line, geometry, and temperature.
35%-40% N-1 coverage
Source: [S4], 2035 shock scenario for graphite + rare earth elements. Use contingency lanes before RFQ freeze.
100% U.S. net reliance (2025)
Source: [S2] heavy rare earth chapter. High-temperature programs should disclose Dy/Tb exposure assumptions.
Gamma (L/D) + direction split
Sources: [S62][S64]. Disc thickness or magnetization-direction changes require fresh demag/load-line evidence before copying prior pilot conclusions.
210 h NSS single-study signal
Sources: [S65][S10]. One Zn-Fe passivation study is useful for screening but not a universal lifecycle guarantee.
ISO 2361 + ISO 1463 + ASTM B571
Sources: [S95][S96][S97]. Disk plating should close lot-level nickel thickness, local edge coverage, and named adhesion checks before PO approval.
Brittle machining signal reported
Source: [S98]. Thin sintered disks need edge-chip reject criteria and fallback review when handling or post-processing loads are non-trivial.
- Engineering teams defining first-pass material lanes before RFQ.
- Procurement teams that need explicit evidence gates before supplier ranking.
- Programs balancing compact size requirements with thermal and corrosion boundaries.
- Teams expecting universal grade answers without duty-cycle evidence.
- Projects that cannot execute minimum thermal/corrosion validation.
- Cost-only sourcing workflows with no fallback lane definition.
2.5) Stage1b gap audit and information deltas
This audit captures where stage1-primary coverage was thin, what evidence was added in stage1b, and which items still need project-specific confirmation.
| Gap identified | Why it was weak | Stage1b information delta | Current state | Source ref |
|---|---|---|---|---|
| Air-shipment compliance blind spot | Stage1-primary emphasized material fit but did not include the package-level magnetic field threshold that can block aircraft carriage. | Added U.S. air-carriage threshold details, decision implications, and minimum logistics actions in key numbers, policy, and open-gap sections. | Closed for first-pass planning; shipment-level field measurement remains mandatory before booking. | [S19] |
| Consumer safety scope ambiguity | Earlier copy focused on industrial sourcing and did not define when consumer magnet safety rules override pure performance screening. | Added 16 CFR hazard criteria, injury context, and FAQ guidance for consumer-channel scope screening. | Closed for U.S. compliance framing; SKU-level exemption interpretation still requires legal/compliance review. | [S20][S21] |
| Recycling vs concentration tradeoff density | The page discussed concentration risk but lacked a concrete demand-versus-secondary-supply baseline for 2024. | Added IEA demand, secondary supply, and concentration figures plus an explicit inferred-ratio label (~30%). | Partially closed; refresh required with each new IEA data cycle. | [S22] |
| US trigger timing visibility | Policy timing focused mainly on EU lanes and omitted immediate U.S. shipment and consumer-rule triggers. | Extended policy matrix with U.S. transport and consumer-safety triggers, each mapped to executable minimum actions. | Closed as of 2026-02-19; monitor CFR updates for scope changes. | [S19][S20] |
| Thin-disc geometry boundary lacked model-backed evidence | Stage1-primary highlighted thin-disc risk but did not connect the claim to finite-cylinder demag references or aspect-ratio model scope. | Added NIST/IEEE and Journal of Applied Physics demag-model evidence, plus explicit gamma-based boundary wording across key numbers, comparison, and boundary sections. | Partially closed as of 2026-02-27; project-specific demag/load-line validation remains mandatory for each critical diameter-thickness family. | [S62][S63] |
| Axial-versus-diametral transfer assumptions were under-specified | Earlier content implied magnetization direction checks were needed but did not show why axial pilot data cannot always certify diametral release. | Added finite-cylinder axial/transverse model evidence, direction-specific comparison guidance, and scenario-level next actions. | Closed for first-pass decision framing; final direction transfer still depends on route-specific simulation and bench evidence. | [S64] |
| Disc coating guidance lacked quantified counterexample and limits | Primary content mentioned coating checks but did not include quantified study data or explicit limits on cross-environment extrapolation. | Added Zn-Fe passivation study figures (210 h neutral salt spray, single-study context) and linked them to ASTM caution against direct life conversion. | Partially closed; no reliable public universal benchmark exists for mixed-media edge-damage lifecycle prediction. | [S65][S10] |
| Disk coating release logic stopped at comparative corrosion headlines | Earlier disk content warned about coating risk but did not tell buyers which thickness or adhesion checks should be named in the RFQ or PO. | Added ISO 2361 nickel-thickness method scope, ISO 1463 local edge-section verification, and ASTM B571 adhesion pass-fail logic across key numbers, comparison, boundary, and FAQ sections. | Partially closed as of 2026-03-26; project-specific media, thermal, and reject-limit correlation still needs finished-part validation. | [S95][S96][S97] |
| Thin-disk handling damage was described qualitatively only | Primary disk copy mentioned edge handling, but it lacked material evidence showing why finished sintered disk edges deserve explicit damage controls and fallback review. | Added scratch and machining evidence for brittle-transition sensitivity, then converted it into disk-only comparison, boundary, open-data, and scenario guidance. | Partially closed as of 2026-03-26; no reliable public chip-size acceptance benchmark exists, so programs still need their own reject-photo and correlation set. | [S98] |
Stage1b evidence refresh completed on 2026-03-26. Re-check disk-family demag assumptions, ISO 2361 lot-thickness method selection, ISO 1463 local edge-section criteria, ASTM B571 adhesion pass sets, and edge-damage reject limits at each quarterly compliance review.
3) Key numbers and scope boundaries
Numeric claims are disclosed with date markers. Unknown or uncertain items are explicitly labeled to avoid false certainty.
| Metric | Value | Date marker | Decision implication | Source ref |
|---|---|---|---|---|
| U.S. rare-earth concentrate output (REO) | 51,000 t and USD 240M | USGS MCS 2026 chapter, published 2026-02 | Shows domestic output scale but not full self-sufficiency for downstream NdFeB supply chains. | [S1] |
| U.S. imports of RE compounds/metals | +169% volume in 2025; value USD 165M vs USD 168M in 2024 | USGS MCS 2026 chapter, published 2026-02 | Procurement risk is driven by product mix and category shifts, not only by headline import value. | [S1] |
| World rare-earth production estimate | 390,000 t in 2025 | USGS MCS 2026 foreword (published 2026-02) | Global supply expanded, but growth does not remove concentration and policy-shock exposure. | [S3] |
| Heavy rare-earth net import reliance (U.S.) | 100% in 2025 (compounds and metals) | USGS MCS 2026 heavy rare earths chapter, published 2026-02 | High-temperature NdFeB lanes can inherit geopolitical and licensing risks through Dy/Tb exposure. | [S2] |
| Rare-earth demand change in STEPS | +50% to +60% by 2040 | IEA Global Critical Minerals Outlook 2025 | Even moderate scenario growth keeps pressure on magnet-material qualification and sourcing plans. | [S4] |
| China projected refining share (battery-grade graphite + rare earths) | Around 80% in 2035 | IEA Global Critical Minerals Outlook 2025 | Dual-lane sourcing should start before RFQ freeze for high-risk temperature classes. | [S4] |
| N-1 supply coverage for graphite + rare earths | Only 35% to 40% of N-1 demand in 2035 | IEA Global Critical Minerals Outlook 2025 | Single-country disruption can invalidate otherwise "balanced" supply assumptions. | [S4] |
| Salt spray as field-life predictor | Seldom correlates when used as stand-alone data | ASTM B117-26, last updated 2026-01-19 | Do not convert fog-test hours directly into service-life commitments without corroborating evidence. | [S10] |
| U.S. net import reliance (RE compounds/metals) | About 67% in 2025 (down from >90% in 2024) | USGS MCS 2026 Rare Earths chapter, published 2026-02 | Dependence improved versus 2024, but import exposure remains high enough to require dual-lane planning. | [S14] |
| U.S. apparent consumption (RE compounds/metals) | 27,000 t REO in 2025 vs 9,010 t in 2024 | USGS MCS 2026 Rare Earths chapter, published 2026-02 | Demand rebound can compress lead-time buffers if RFQ and validation gating are delayed. | [S14] |
| China share of U.S. RE imports by value | Average 71% (2021-2024) | USGS MCS 2026 Rare Earths chapter, published 2026-02 | Country concentration remains material for NdFeB programs even when domestic mine output increases. | [S14] |
| Rare-earth oxide price dispersion (2025, China market) | NdPr +25% ($55->69/kg), Tb +24% ($812->1,010/kg), Dy -7% ($257->239/kg) | USGS MCS 2026 Rare Earths + Heavy Rare Earths chapters | Do not treat heavy-RE exposure as one blended surcharge; element-specific terms are safer for contracts. | [S14][S15] |
| Chinese permanent-magnet exports | About 58,000 t in 2024 | IEA commentary on export controls, published 2025-12-04 | Short approval delays can rapidly affect downstream inventories when market dependence is high. | [S16] |
| EU strategic benchmark package (CRMA) | 2030 targets: 10% extraction, 40% processing, 25% recycling, <=65% single-country dependency | Regulation (EU) 2024/1252, effective 2024-05-23 | EU-facing RFQs should include origin traceability and recycling disclosure gates before final award. | [S12] |
| Air carriage magnetic-field limit (U.S.) | >0.00525 gauss at 4.5 m from any package surface is forbidden | FAA PackSafe page last updated 2023-03-15; eCFR current to 2026-03-19 | Technical fit alone does not guarantee ship readiness; package-field checks must be part of launch gating. | [S19] |
| U.S. consumer magnet hazard threshold | Hazard criteria include small-part fit plus flux index >=50 kG2 mm2; subject products must stay below 50 | 16 CFR part 1262 current text, accessed 2026-02-19 | Consumer-facing loose-magnet products need compliance screening before using catalog strength claims in go-to-market plans. | [S20] |
| U.S. high-powered magnet injury baseline | Estimated 26,600 emergency-department visits (2010-2021) and 7 reported deaths | 16 CFR part 1262 findings and CPSC final-rule release (2022) | If magnets can become loose parts, safety risk can dominate material-choice logic even when force targets are met. | [S20][S21] |
| Rare-earth demand vs secondary supply (2024, STEPS) | 91 kt demand vs 27 kt secondary supply (~30%, inferred) | IEA rare-earth data page, updated 2025-05-21 | Secondary supply helps but does not replace primary extraction and refining resilience planning. | [S22] |
| Top-three concentration (2024, STEPS) | Mining 86%; refining 97% | IEA rare-earth data page, updated 2025-05-21 | Supplier-count diversification can still mask concentration risk if upstream refining remains highly clustered. | [S22] |
| Finite-cylinder demag model coverage for disc geometry | Nf and Nm were calculated for 0.01 <= gamma <= 50 (2D model), with one-dimensional extension from gamma >= 10 | IEEE Transactions on Magnetics 27(4), published 1991-07 | Thin-disc aspect ratio shifts demagnetizing behavior enough to require geometry-aware checks before grade lock. | [S62] |
| Cylinder demag quick-approximation error band | Sato-Ishii approximation for uniformly magnetized cylinders reports <4.25% error for n < 100 (n = length/diameter) | Journal of Applied Physics publication date 1989-07-15 | Fast screening formulas are useful for disc RFQ triage, but teams must still validate assumptions with program-specific models. | [S63] |
| Axial-versus-transverse finite-cylinder formula availability | 3D Maxwell-based approximate formulas were reported for finite cylinders in axial and transverse fields | Physical Review Applied 10, published 2018-07-01 | Axial and diametral magnetization routes should not be treated as interchangeable without direction-specific checks. | [S64] |
| Disc-coating single-study benchmark (Zn-Fe with Cr(III)) | A 0.9 wt.% Fe passivated Zn-Fe coating endured 210 h neutral 3.5 wt.% NaCl spray without white rust (3-4x pure Zn) | Materials (MDPI) 15(21):7523, published 2022-10-27 | Coating stack decisions can materially shift disc durability, but one study is not enough for universal lifecycle claims. | [S65] |
| Electroplated nickel thickness method window | ISO 2361:2025 scope summary says magnetic-attraction method is effective from 0 to 50 um, while reluctance instruments extend from 0 to 1 mm | ISO 2361:2025 page published 2025-06; accessed 2026-03-26 | Disk-magnet Ni or e-nickel control plans can use non-destructive lot screening, but the chosen method and substrate route must stay fixed in the released inspection plan. | [S95] |
| Local edge-thickness verification route for plated disks | ISO 1463:2021 defines a microscopical cross-section method for local coating thickness determination | ISO 1463:2021 page published 2021-06; accessed 2026-03-26 | Average face thickness does not close thin-disk edge risk when corrosion or handling damage concentrates at the rim. | [S96] |
| Adhesion pass-fail rule for plated disk release | ASTM B571-23 says that when multiple adhesion tests are used, failure of any one means the coating is unsatisfactory | ASTM B571-23 page updated 2023-11-03; accessed 2026-03-26 | POs should name the post-treatment adhesion checks to run instead of accepting a generic "nickel plated" declaration. | [S97] |
| Sintered NdFeB machining damage signal | A 2023 scratch study on sintered N42 magnets reported anisotropic ductile-brittle transition depths around 250.8 to 271.2 nm | Journal of Manufacturing Processes, published 2023-05-26 | Thin disks need explicit edge-chip controls during grinding, plating prep, packaging, and incoming inspection instead of relying on cosmetic-only review. | [S98] |
Note: Grade suffix windows shown here are supplier planning conventions. Final qualification always depends on measured magnetic curves, thermal reserve checks, and application-specific validation.
Evidence refresh timestamp for this section: 2026-03-26.
Share your duty profile, shipment lane, and channel assumptions. We will return an RFQ-ready action list with fallback triggers.
3.5) Policy and compliance trigger matrix (neodymium route)
This section adds time-bound regulatory and market triggers that materially change NdFeB procurement decisions for EU-facing and globally exposed programs.
| Trigger | What changed | Timing | Sourcing impact | Minimum action | Source ref |
|---|---|---|---|---|---|
| EU strategic benchmark gate (CRMA Article 5) | EU defines 2030 targets: >=10% extraction, >=40% processing, >=25% recycling, and <=65% single-country dependency. | Regulation in force since 2024-05-23; benchmark horizon is 2030. | EU-bound programs need upstream origin transparency and backup processing lanes earlier in the RFQ cycle. | Request country-of-processing disclosure and contingency sources before price-only negotiations. | [S12] |
| Permanent-magnet label and digital data carrier (CRMA Article 28) | Products containing permanent magnets in covered categories must carry recycler-readable labels and a data carrier. | Delegated act due by 2026-11-24; obligations apply two years after delegated act enters into force. | Packaging and traceability workflows may need redesign if label/data fields are not planned upfront. | Insert label-readiness clauses in supplier agreements and reserve packaging change budget before SOP. | [S13] |
| Recycled-content statement for magnets (CRMA Article 29) | For products with >0.2 kg permanent magnets, recycled-content share for Nd, Dy, Pr, Tb and related elements must be disclosed. | Applies from 2027-05-24 or two years after delegated methodology act, whichever is later. | Quotes without elemental recycled-content accounting can become non-comparable for EU programs. | Add recycled-content traceability fields to RFQ templates and require method disclosure with each quote revision. | [S13] |
| 2025 export-control disruption window | IEA reports licensing restrictions and approval bottlenecks after China export-control tightening in 2025. | Controls announced 2025-04 and extended by 2025-10; approvals remained constrained through 2025-11. | Single-lane NdFeB sourcing can face abrupt lead-time shocks even when nominal capacity exists. | Define trigger-based switch rules (lead time, surcharge, and element exposure) before final supplier award. | [S15][S16] |
| Corrosion test comparability gate | ISO 9227 and IEC 60068-2-11 define controlled salt-mist methods, but they remain comparative screening tools rather than direct field-life predictors. | ISO 9227 published 2022-08; IEC 60068-2-11 updated 2021-06-17; ASTM B117 current revision 2026-01-19. | Quote claims based only on fog-test hours can overstate lifecycle confidence across real media and duty cycles. | Require combined corrosion + thermal-cycle validation criteria in RFQ instead of accepting stand-alone salt-spray hours. | [S10][S17][S18] |
| U.S. air-carriage magnetized-material gate | FAA PackSafe and 49 CFR 173.21(d) align on the aircraft carriage limit of >0.00525 gauss at 4.5 m from any package surface. | FAA page last updated 2023-03-15; eCFR current to 2026-03-19. | High-strength packages can require shielding redesign or route changes even after technical material fit is approved. | Add package-field measurement records to logistics release checklists before air-freight booking. | [S19] |
| U.S. consumer loose-magnet safety gate | 16 CFR part 1262 defines hazardous consumer magnet products by small-part fit and flux index threshold; CPSC attributes major injury burden to this category. | Effective since 2022-10-21; current text accessed 2026-02-19. | Consumer-facing SKUs can fail compliance even when engineering pull-force targets are met. | Screen product scope and flux-index risk before tooling and packaging lock for consumer channels. | [S20][S21] |
| Pending item | Current status | Impact | Minimum action | Source ref |
|---|---|---|---|---|
| CRMA Article 28 magnet-label implementation template | Pending delegated act text (deadline 2026-11-24). As of 2026-02-18, no reliable public final label template is available. | Teams may under-scope packaging, serialization, or data-carrier changes if they wait for late-stage interpretation. | Track Official Journal updates monthly and require suppliers to provide draft label/data payload mapping in advance. | [S13] |
| CRMA Article 29 recycled-content calculation method | Delegated methodology act is due by 2026-05-24; as of 2026-02-18, no reliable public finalized method text is available. | Supplier recycled-content declarations may use inconsistent assumptions, reducing quote comparability. | Ask each supplier for current method assumptions and third-party verification path until EU method is finalized. | [S13] |
| Part-level Dy/Tb intensity for specific commercial grades | No reliable public open dataset; supplier formulas are typically confidential and program-specific. | Element-specific price and export-license exposure can remain hidden until late quote revisions. | Use NDA-backed composition range disclosure and element-indexed surcharge clauses before committing long-horizon POs. | [S15] |
| Carrier-specific acceptance workflow for magnetized packages | No single reliable public cross-carrier template; regulatory thresholds are clear but acceptance workflows vary by route and operator. | Programs can hit late booking friction even after in-house technical and compliance reviews pass. | Collect route-specific carrier checklists and sample package-field evidence before ramp milestones. | [S19] |
Pending labels use explicit status wording when no reliable public implementation text is available as of 2026-03-26.
4) Methodology
The method combines technical feasibility and sourcing execution in one path so output can directly drive next actions.
Step 1 - Convert max and peak temperatures into planning duty
For this neodymium magnets route, the tool adjusts both max operating and peak temperatures, then applies an 8C planning guard band on sustained duty.
Step 2 - Gate against thermal class and flux demand
Planning duty maps to N/AH planning windows while requested flux density screens for sintered, bonded, or fallback routes.
Step 3 - Add coating and validation burden
Corrosion exposure determines coating stack and required validation evidence before RFQ lock.
Step 4 - Produce action path with confidence
The output reports confidence, risk rows, and next actions so teams can move directly into RFQ or fallback planning.
Step 5 - Add disc geometry and magnetization-direction demag gates
For disc routes, the workflow appends aspect-ratio (gamma) checks and axial-vs-diametral evidence requirements so thin-disc assumptions are not transferred blindly between configurations.
Step 6 - Convert coating claims into edge-focused validation tasks
Disc pages treat coating studies as comparative inputs only, then require program-specific mixed-media and edge-condition closure before RFQ lock.
Step 7 - Freeze a disk-only coating release stack before PO approval
For the neodymium magnets disk route, stage1b adds a named control stack: ISO 2361 lot-thickness screening, ISO 1463 local edge verification, ASTM B571 post-treatment adhesion checks, and explicit edge-damage reject criteria.
5) Data sources and evidence trail
Every key conclusion maps to a source and date marker so reviewers can validate or challenge assumptions quickly.
| Ref | Source | Signal used on this page | Date marker |
|---|---|---|---|
| S1 | USGS MCS 2026 - Rare Earths chapter | Reports U.S. REO concentrate output (51,000 t, USD 240M) and import shift (+169% volume; value USD 165M vs USD 168M in 2024). | Published 2026-02 |
| S2 | USGS MCS 2026 - Heavy Rare Earths chapter | Shows U.S. net import reliance at 100% in 2025 and documents 2025 export-control timeline affecting heavy rare earths. | Published 2026-02 |
| S3 | USGS Mineral Commodity Summaries 2026 (foreword) | States world rare-earth production estimate reached 390,000 tons in 2025. | Manuscript approved 2026-02-06 |
| S4 | IEA Global Critical Minerals Outlook 2025 | Rare-earth demand rises 50%-60% by 2040 in STEPS; China around 80% refining share in 2035; N-1 coverage for graphite + rare earths only 35%-40%. | Published 2025 |
| S5 | DOE Critical Materials Assessment 2023 | Executive summary states Nd, Pr, Dy, Tb used in EV motor and wind generator magnets continue to be critical. | Published 2023-07-31 |
| S6 | IEC 60404-5:2015 | Defines measurement methods for magnetic flux density, polarization, field strength, demagnetization curve, and recoil line for permanent magnets. | Publication date 2015-04-16 |
| S7 | IEC 60404-8-1:2023 | Specifies minimum magnetic-property values and dimensional tolerances for magnetically hard materials, including updated REFeB grades. | Publication date 2023-09-20 |
| S8 | IEC 60404-18:2025 | Defines open-circuit superconducting-magnet methods (SCM-VSM and SCM-extraction) and self-demagnetizing-field corrections. | Publication date 2025-02-20 |
| S9 | IEC TR 62518:2009 | Details flux-loss behavior of Nd-Fe-B and SmCo sintered magnets from 50C to 200C for up to 1000 h; explicitly excludes corrosion-coupled stability modeling. | Publication date 2009-03-17 |
| S10 | ASTM B117-26 | Defines salt-spray apparatus as a controlled comparative test and warns that stand-alone correlation to natural environment is seldom reliable. | Last updated 2026-01-19 |
| S11 | Review paper on bonded NdFeB (Journal of Alloys and Compounds 2025) | Notes isotropic bonded NdFeB is often <=16 MGOe while anisotropic bonded routes can approach ~25 MGOe. | Published 2025-07-15 |
| S12 | Regulation (EU) 2024/1252 (CRMA), Article 5 | Sets 2030 EU benchmarks: >=10% extraction, >=40% processing, >=25% recycling, and <=65% single-country dependency at each strategic stage. | Entered into force 2024-05-23 |
| S13 | Regulation (EU) 2024/1252 (CRMA), Articles 28-29 | Defines permanent-magnet labeling/data-carrier obligations and recycled-content statement requirements for Nd, Dy, Pr, Tb and related elements. | Entered into force 2024-05-23 |
| S14 | USGS MCS 2026 - Rare Earths chapter | Reports U.S. 2025 net import reliance at about 67%, consumption at 27,000 t REO, China import share averaging 71% (2021-2024), and NdPr oxide rising from $55/kg to $69/kg in 2025. | Published 2026-02 |
| S15 | USGS MCS 2026 - Heavy Rare Earths chapter | Documents 2025 export-control timeline for seven medium/heavy rare-earth items; terbium oxide increased from $812/kg to $1,010/kg while dysprosium oxide declined from $257/kg to $239/kg. | Published 2026-02 |
| S16 | IEA commentary: China’s export restrictions and strategic responses | Notes roughly 58,000 t Chinese permanent-magnet exports in 2024 and reports 2025 licensing disruptions affecting downstream inventories. | Published 2025-12-04 |
| S17 | ISO 9227:2022 Corrosion tests in artificial atmospheres | Defines NSS/AASS/CASS test methods and warns that salt-spray performance does not translate directly into corrosion behavior in other environments. | Published 2022-08 |
| S18 | IEC 60068-2-11:2021 Environmental testing - Test Ka | Provides an electrotechnical salt-mist test protocol used for comparative corrosion qualification and test reproducibility. | Published 2021-06-17 |
| S19 | FAA PackSafe magnets page + 49 CFR 173.21(d) | States that any package or magnet above 0.00525 gauss at 4.5 m (15 feet) from any package surface cannot fly and points to the codified DOT rule. | FAA page last updated 2023-03-15; accessed 2026-03-22 |
| S20 | eCFR 16 CFR part 1262 - Safety standard for magnets | Defines hazard criteria using small-part fit and flux index >=50 kG2 mm2, with an effective date of 2022-10-21. | Current text (last amended 2023-09-20), accessed 2026-02-19 |
| S21 | CPSC final-rule release for magnet safety | Reports estimated 26,600 emergency-department visits (2010-2021) and seven deaths linked to high-powered magnet ingestion incidents. | Published 2022-09-22 |
| S22 | IEA data: Rare earth elements supply, demand, diversification and policy support | Shows 2024 STEPS values of 91 kt demand, 27 kt secondary supply, and top-three concentration of 86% (mining) and 97% (refining). | Updated 2025-05-21 |
| S62 | NIST/IEEE (1991) Demagnetizing factors for cylinders (Chen, Brug, Goldfarb) | Defines finite-cylinder demagnetizing factors as functions of susceptibility and aspect ratio gamma = length/diameter, with two-dimensional calculations covering 0.01 <= gamma <= 50. | Published 1991-07-01; NIST page updated 2017-08-30 |
| S63 | Journal of Applied Physics 66(2): Simple and approximate expressions of demagnetizing factors of uniformly magnetized rectangular rod and cylinder (Sato, Ishii) | Abstract reports a cylinder approximation with relative error under 4.25% for n < 100 (n = length/diameter), supporting quick demag screening before full modeling. | Published 1989-07-15 |
| S64 | Physical Review Applied 10 (2018): Effective demagnetizing factors of diamagnetic samples of various shapes | Provides approximate formulas from 3D Maxwell equations for finite cylinders in both axial and transverse field configurations. | Published 2018-07-01 |
| S65 | Materials 15(21):7523 (2022) Zn-Fe alloy coatings and Cr(III) passivation on sintered NdFeB magnets | Reports that a low-iron Zn-Fe coating with 0.9 wt.% Fe plus Cr(III) passivation sustained 210 h neutral salt-spray exposure without white rust and outperformed pure Zn in the same study. | Published 2022-10-27 |
| S95 | ISO 2361:2025 Electroplated nickel coatings and related finishes on magnetic and non-magnetic substrates | The ISO scope summary states that magnetic-attraction measurements are effective from 0 to 50 um and reluctance-instrument measurements from 0 to 1 mm for electroplated nickel thickness checks. | Published 2025-06; page accessed 2026-03-26 |
| S96 | ISO 1463:2021 Metallic and oxide coatings - Measurement of coating thickness - Microscopical method | Defines the microscopical cross-section method for local coating thickness determination, which is useful when disk edges or corners need local verification rather than average-only screening. | Published 2021-06; page accessed 2026-03-26 |
| S97 | ASTM B571-23 scope page (qualitative adhesion testing) | Defines qualitative adhesion test methods for metallic coatings and states that if multiple tests are used, failure of any one means the coating is unsatisfactory. | Last updated 2023-11-03; active status checked 2026-03-26 |
| S98 | Journal of Manufacturing Processes (2023): anisotropic ductile-brittle transition in sintered N42 magnets | Reports anisotropic scratch and machining behavior with ductile-brittle transition depths around 250.8 to 271.2 nm, indicating that finished sintered NdFeB edges remain damage-sensitive during post-processing. | Published 2023-05-26 |
Neodymium magnets disk stage1b refs [S12]-[S22] plus [S62]-[S65] and [S95]-[S98] refreshed on 2026-03-26.
6) Concept boundaries and applicability rules
These boundaries are used to prevent over-interpretation of catalog labels and to define where additional evidence is mandatory.
| Boundary | Meaning | Use when | Do not use when | Source ref |
|---|---|---|---|---|
| BHmax headline is not assembly force | Energy-product labels compare material potential, not guaranteed pull force in your magnetic circuit. | Use BHmax as first-pass screening with geometry and load-line assumptions declared. | Do not rank suppliers by BHmax alone when measurement method or working point is undisclosed. | [S6][S7][S8] |
| Grade suffix is a planning shortcut | N/M/H/SH/UH/EH/AH ranges are commonly used in commerce but are not a standalone release criterion. | Use suffix classes for early lane gating before detailed BH-curve and demag checks. | Do not treat suffix labels as universal guarantees across vendors without material test disclosure. | [S6][S7] |
| Salt spray is comparative, not life prediction | Salt-fog testing helps compare coating options in controlled chambers. | Use as a screening gate with replication and clear acceptance criteria. | Do not map salt-spray hours directly to field-life commitments without corroborating long-term exposure data. | [S10] |
| High-temperature NdFeB can raise heavy-RE exposure | Programs near EH/AH lanes can become more sensitive to Dy/Tb availability and export controls. | Trigger dual-lane sourcing and fallback windows before RFQ lock when adjusted peak duty is high. | Do not assume global supply expansion alone removes element-specific licensing or concentration risks. | [S2][S4][S5] |
| Thermal stability data has defined scope | Published stability studies include specific time/temperature windows and may exclude corrosion-coupled behavior. | Use the tested windows (for example 50C to 200C, up to 1000 h) as boundary references only. | Do not extrapolate beyond reported conditions without additional testing for corrosion, duty cycling, and geometry effects. | [S9] |
| Air-shipment eligibility is package-level | Air transport screening uses measured package field at distance, not grade labels or nominal BHmax claims. | Apply before booking aircraft lanes for strong assemblies, kits, or mixed shipments. | Do not assume a magnet is flyable because the material passes engineering performance targets. | [S19] |
| Consumer magnet safety scope is conditional | U.S. 16 CFR part 1262 addresses consumer products containing hazardous loose magnets defined by size and flux index. | Use when end products can release accessible loose magnets in consumer channels. | Do not overgeneralize as a universal industrial exemption; verify product scope and exemptions first. | [S20][S21] |
| Disc diameter-to-thickness ratio is a hard gate, not a style choice | Finite-cylinder demagnetizing behavior changes with aspect ratio gamma = length/diameter, so thin discs can lose usable reserve even when catalog grade looks sufficient. | Use when disc thickness or air-gap changes can shift load-line margin near release windows. | Do not assume one pull-force sample from a thicker prototype transfers directly to thinner production discs. | [S62][S63] |
| Axial and diametral magnetization evidence is not interchangeable | Finite-cylinder models treat axial and transverse fields differently, so direction-specific validation is required for each disc route. | Use when changing polarity map, assembly orientation, or sensor geometry between pilot and production. | Do not reuse axial test data as proof for diametral release without equivalent direction-specific evidence. | [S64] |
| One coating study cannot become a universal disc-life promise | Published Zn-Fe passivation gains are useful signals, but ASTM B117 still treats chamber exposure as comparative screening rather than direct field-life prediction. | Use when ranking candidate coating stacks and defining pilot test windows for disc edges. | Do not convert one salt-spray result into blanket lifecycle commitments across different media, handling loads, and duty cycles. | [S65][S10] |
| Average nickel thickness is not a disk-edge release decision | ISO 2361 supports fast lot-level thickness checks, but ISO 1463 still matters when local edge coverage decides corrosion life on thin disks. | Use when plated disks will see humid, washdown, or edge-contact duty and corrosion starts at local coverage weak points. | Do not approve a plated disk family from one face-average thickness value when the rim or edge is the dominant failure surface. | [S95][S96] |
| Finished-disk adhesion must be defined after post-treatment | ASTM B571 provides qualitative adhesion methods and states that failing any chosen test makes the coating unsatisfactory, so the selected post-treatment checks must be named in the release plan. | Use when suppliers quote nickel, e-nickel, or multi-layer stacks and approval depends on more than a plating certificate. | Do not treat an unspecified "passed adhesion" statement as equivalent to a named ASTM B571 method set on the finished disk geometry. | [S97] |
| Thin sintered disk handling damage is a real release gate | Published machining evidence shows sintered NdFeB remains brittle and damage-sensitive, so edge chips are not just cosmetic if they later drive corrosion or assembly fallout. | Use when disk thickness is low, handling is manual, or the production route includes grinding, plating prep, tumbling, or tight packout density. | Do not assume a visually clean pilot lot proves the production lane is robust if edge-damage controls were not specified and audited. | [S98] |
7) Material comparison and tradeoffs
Compare material routes using reproducible dimensions instead of marketing-only descriptors.
| Decision dimension | Sintered NdFeB | Bonded NdFeB | SmCo | Comment | Source ref |
|---|---|---|---|---|---|
| Typical magnetic energy density window | 28-53 MGOe | <=16 MGOe (isotropic), up to ~25 MGOe (anisotropic) | 20-33 MGOe | Values are orientation windows from cited source sets; geometry and working point still shift usable output. | [S11] |
| Planning temperature ceiling | Commercial planning classes often run through AH around 220C (verify by curve and load-line) | Typically lower than sintered due to polymer binder constraints | Used as high-temperature fallback; IEC TR 62518 discusses elevated-temperature stability behavior | Use adjusted peak temperature, not ambient. Final limit must come from vendor curves under your duty profile. | [S9] |
| Shape freedom and manufacturing | Strong but brittle; machining tolerance management is critical | Higher shape freedom for complex and thin-wall geometries | Brittle ceramic-like behavior; machining control required | Shape complexity can justify bonded routes even when peak BHmax is lower. | [S11] |
| Corrosion baseline | Coating usually required (Ni-Cu-Ni, epoxy, or equivalent) | Binder contributes baseline protection but media compatibility must still be verified | Better inherent corrosion behavior in many environments | ASTM B117 / IEC 60068-2-11 are gate checks, not direct life models. | [S10] |
| Supply concentration exposure (2035 view) | High for Nd/Pr, and potentially Dy/Tb in high-temperature coercivity lanes | Still tied to rare-earth feedstock plus binder/process dependencies | Different critical-material exposure profile (includes cobalt) | IEA N-1 analysis shows concentration shock can leave only 35%-40% coverage for rare-earth linked chains. | [S4] |
| Measurement comparability baseline | Require demag curve + recoil line under disclosed method | Request the same measurement family and working-point disclosure | Normalize by same method before ranking across vendors | IEC 60404-5 and IEC 60404-18 describe measurement methods; IEC 60404-8-1 defines minimum property specifications. | [S6][S7][S8] |
| Best-fit program conditions | General high-flux motors, sensors, compact electromechanics | Complex geometry, high-volume molding, lower peak flux density demands | Very high-temperature or severe thermal-cycle duty | Always close loop with demag, corrosion, and thermal evidence before release. | [S5][S9] |
| Logistics and consumer-compliance friction | High-field packages can breach air-carriage thresholds; loose consumer magnet formats need explicit safety screening. | Lower energy density can reduce some package-field pressure, but product-level safety checks still apply. | No automatic exemption; package-field and end-use safety scope must still be verified. | Inference from [S11][S19][S20]: compliance is tested at package/product level, not guaranteed by material family alone. | [S11][S19][S20] |
| Disc aspect ratio and demag reserve sensitivity | Thin discs can lose internal-field reserve quickly as length/diameter ratio drops, so grade-only selection is unreliable. | Can reduce machining brittleness for thin geometries, but lower energy density often requires volume compensation. | Offers thermal fallback, yet finite-cylinder demag behavior still needs geometry-specific validation. | Use [S62][S63] to document gamma assumptions before comparing disc quotes. | [S62][S63] |
| Axial versus diametral (transverse) magnetization transfer risk | Direction-specific demag behavior means axial validation cannot be copied into diametral releases. | More isotropic routes can ease direction sensitivity, but still require orientation checks for final assembly fields. | Chemistry change does not remove orientation-specific field modeling requirements. | Counterexample from [S64]: finite cylinders need separate axial/transverse treatment in analytical models. | [S64] |
| Disc-edge coating option evidence quality | Conventional Ni-based stacks are common, but disc-edge durability claims should include media, cycle, and passivation details. | Binder helps certain corrosion paths, yet aggressive media and edge handling still require validation. | Better intrinsic corrosion behavior in many cases, but coating/process evidence remains application-dependent. | Single-study signal [S65] plus ASTM caution [S10]: chamber wins are comparative, not universal life guarantees. | [S65][S10] |
| Disk coating release evidence stack | Plated sintered disks should pair lot-level thickness screening, local edge-section checks, and explicit post-treatment adhesion criteria before release. | Binder-heavy routes can reduce reliance on full-metal coating in some programs, but media compatibility and aging evidence are still required. | Intrinsic chemistry can reduce some corrosion pressure, yet edge protection and adhesion checks remain application-dependent. | Use [S95][S96][S97] together; one average thickness value is not a release pack for thin disks. | [S95][S96][S97] |
| Thin-disk edge-damage tolerance versus material fallback | Scratch and machining evidence shows brittle-transition sensitivity, so thin disks need edge-chip controls during finishing, packout, and incoming inspection. | Near-net-shape routes can reduce chip risk, but lower magnetic energy often forces diameter or stack-height concessions. | Thermal and corrosion margin can improve, but brittle handling risk does not disappear just because chemistry changes. | Use [S98][S11] to compare edge-damage tolerance against energy-density tradeoffs before forcing a sintered-disk lane. | [S98][S11] |
| Coupon-to-finished-disk transfer risk | Flat coupon or face-only plating data does not automatically prove finished-disk edge coverage or adhesion after final post-treatment. | Molded or coated samples can reduce transfer error, but assembly-specific aging still needs verification. | Finished-part geometry still controls whether coupon data is trustworthy for production release. | Counterexample from [S96]: local thickness verification exists precisely because geometry-sensitive coverage cannot be closed by average-only assumptions. | [S96] |
8) Risk matrix and mitigation
Misuse risk, cost risk, and scenario mismatch risk are shown together so the team can sequence mitigation actions.
| Risk | Probability | Impact | Mitigation |
|---|---|---|---|
| Thermal misclassification versus real hotspot duty | Low | Medium | Recalculate adjusted operating + peak duty with measured cycle data and confirm class with demag-curve checks before PO. |
| Coating-lifecycle mismatch under real media exposure | Medium | Medium | Map media profile to explicit corrosion + thermal-cycle tests and define pass/fail criteria up front. |
| Supplier data non-comparability (test method mismatch) | Medium | Medium | Require method disclosure (IEC 60404 family) and normalize working points before ranking quotes. |
| High-temperature lane heavy-rare-earth exposure | Medium | Medium | When adjusted duty approaches EH/AH lanes, request Dy/Tb exposure disclosure and define export-control fallback triggers before award. |
| Supply concentration shock during launch window | High | Medium | Maintain contingency lane and pre-define switch triggers for temperature, lead time, and cost tolerance. |
| Disc geometry transfer mismatch (thickness and direction) | Medium | High | Treat each diameter/thickness family and direction as separate release evidence; do not transfer axial or thicker-disc conclusions without re-validation. |
9) Open evidence gaps and minimum closure path
Where public evidence is incomplete, this page does not force a hard conclusion. Each gap includes a minimal executable closure action.
| Evidence gap | Current status | Decision impact | Minimum closure action | Source ref |
|---|---|---|---|---|
| Cross-supplier suffix mapping to guaranteed demag margin | No single public standard mapping N/M/H/SH/UH/EH/AH suffix labels to guaranteed in-application demag reserve. | Quote comparisons can look equivalent while actual thermal headroom differs by method and working point. | Request vendor-specific BH curves, recoil data, and temperature conditions before release decisions. | [S6][S7] |
| Salt-spray hours to field-life conversion | No reliable universal conversion model in open standards; ASTM B117 warns stand-alone correlation is seldom robust. | Warranty and lifecycle assumptions can be overstated if fog-hour data is treated as direct service-life evidence. | Pair chamber tests with application-specific thermal/media cycling and clearly documented acceptance criteria. | [S10] |
| Corrosion-coupled high-temperature flux-loss dataset for each coating stack | Public IEC thermal-stability report excludes corrosion-coupled behavior modeling for full lifecycle prediction. | High-temperature and aggressive-media programs may underestimate long-term drift and reserve loss. | Run combined thermal + corrosion + load-line validation for each candidate stack before final PO. | [S9] |
| Program-specific heavy-rare-earth exposure breakdown | Public macro data confirms concentration risk, but part-level Dy/Tb intensity is typically supplier-confidential. | Lead-time and export-license risk can remain hidden until late sourcing stages. | Add material disclosure checkpoints and contingency triggers in RFQ templates. | [S2][S4] |
| Package-field prediction from CAD/BHmax alone | No reliable universal public model converts part-level grade and geometry into certified package-field outcomes at transport distance. | Teams can discover non-compliant shipping configurations late, after packaging design and launch schedules are locked. | Run measured package-field checks on shipment-ready units and reserve shielding iteration time before booking. | [S19] |
| Disc geometry to in-circuit force retention transfer model | No reliable public multi-supplier dataset maps NdFeB disc aspect ratio (gamma), magnetization direction, and thermal duty into one auditable pull-force retention model. | Teams can over-trust room-temperature sample force and miss demag-margin collapse after thickness or direction changes. | Require direction-specific demag/load-line evidence for each critical diameter-thickness family before supplier lock. | [S62][S64] |
| Cross-stack corrosion benchmark for disc edges under mixed duty | No reliable public benchmark compares major commercial disc coating stacks under combined humidity, salt, thermal cycling, and handling-edge damage in one normalized protocol. | Programs can choose coating by single-test headlines and discover field failures after launch. | Treat published coating wins as hypothesis inputs, then run program-specific mixed-media tests with edge-focused acceptance criteria. | [S65][S10] |
| No public release benchmark links average nickel data to local disk-edge life | No reliable public cross-supplier dataset converts ISO 2361 lot-level nickel thickness, ISO 1463 local edge sections, and ASTM B571 adhesion checks into a field-life prediction for NdFeB disks. | Teams can close coating review on face-average values and still miss edge-driven corrosion or fallout after launch. | Write a disk-specific release stack that names lot-level thickness method, local edge-section criteria, adhesion checks, and media/thermal validation before PO approval. | [S95][S96][S97][S10] |
| Public edge-chip acceptance threshold for thin sintered disks | No reliable public benchmark quantifies what chip size, scratch depth, or edge damage remains acceptable before corrosion or assembly performance becomes unacceptable for thin NdFeB disks. | Incoming inspection can pass cosmetic review while hidden damage still erodes corrosion margin or assembly yield. | Define project-specific edge-damage photos, reject limits, and correlation checks to corrosion and assembly outcomes before volume release. | [S98] |
Labeling policy: when reliable public data is insufficient, status is marked as "no reliable public data" and converted into a validation task instead of a forced conclusion.
10) Scenario examples
Each scenario includes assumptions, tool outcome, and minimum executable next step.
Assumptions
Peak 145C, humid but sealed enclosure, target flux 820 mT, annual volume 120k.
Outcome
Fit: SH/UH sintered NdFeB lane with epoxy-over-Ni coating and standard validation depth.
Next step
Proceed with NdFeB primary lane and run salt-mist + thermal cycle validation before pilot freeze.
Assumptions
Peak 198C, coolant splash exposure, target flux 960 mT, annual volume 45k, automotive compliance.
Outcome
Conditional: EH/AH planning window with tighter demag reserve checks and contingency lane recommendation.
Next step
Open parallel SmCo contingency lane until demag and corrosion evidence both pass program criteria.
Assumptions
Peak 238C, high corrosion medium, target flux 680 mT, low annual volume, medical-grade audit controls.
Outcome
Not fit: adjusted thermal duty exceeds AH planning envelope for NdFeB.
Next step
Prioritize SmCo fallback or architecture redesign before spending cycle budget on high-risk NdFeB trials.
Assumptions
Peak 172C, humid industrial floor, target flux 910 mT, annual volume 80k, products destined for EU compliance lanes.
Outcome
Conditional: NdFeB is technically feasible but procurement path is gated by CRMA traceability and recycled-content disclosure readiness.
Next step
Hold dual-source lane and lock supplier traceability payload (origin + recycled content assumptions) before line-freeze milestone.
Assumptions
Disc diameter kept at 16 mm while thickness drops from 3.0 mm to 1.8 mm, peak 128C, humid cleaning exposure, and unchanged force target from prior pilot.
Outcome
Conditional: baseline grade can remain feasible, but demag reserve and orientation assumptions are no longer transferable from the thicker pilot part.
Next step
Re-run axial/diametral direction checks with updated aspect ratio and block RFQ release until load-line plus coating-edge evidence closes.
Assumptions
12 x 1.2 mm sintered NdFeB disks, axial magnetization, humid cleaning duty, nickel-plated lot with acceptable average face thickness but no local edge sections or post-treatment adhesion data.
Outcome
Conditional: magnetic fit remains feasible, but release confidence is weak because coating evidence is incomplete for the actual disk edge geometry.
Next step
Hold supplier award until the lot adds local edge-section verification, named adhesion tests, and media-specific corrosion plus thermal validation on finished disks.
Assumptions
10 x 0.8 mm sintered disks, diametral direction, moderate flux target, frequent manual loading, dense packaging, and recurring volume above 100k units.
Outcome
Conditional bordering on not-fit: geometry and handling remain possible, but chip risk and demag-transfer risk justify keeping bonded NdFeB or SmCo contingency lanes open.
Next step
Split the RFQ into sintered and fallback lanes, define edge-damage rejects with photo standards, and close the decision only after finished-part handling plus load-line evidence agrees.
11) FAQ (decision-focused)
Questions are grouped by decision intent so teams can move from explanation to execution.
12) Next action
Share your duty profile and we will return a material-lane recommendation with grade window, coating strategy, validation checklist, and RFQ normalization notes.
Product Gallery
High-grade disc magnets
Specifications
| Primary geometry lane | Round sintered NdFeB disc magnets for encoders, rotor stacks, couplings, and compact closure modules |
| Disc-thickness planning boundary | Thin discs increase edge-chip and coating-coverage risk, requiring handling and inspection controls before release |
| Magnetization planning | Axial or diametral magnetization selected by flux path, air-gap design, and orientation tolerance |
| Typical grade planning | N35-N52 baseline with SH/UH fallback lanes when adjusted duty temperature or coercivity margin tightens |
| Tool output payload | Fit band, confidence score, boundary note, and result-specific next actions for quote normalization |
| RFQ release gate | Supplier award requires method-normalized geometry, thermal, corrosion, and magnetization evidence |
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Reference Guides
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Storage, handling, and packaging guidance to avoid chipping, demagnetization, and injury.
Case studies
HVAC - Linear actuator assemblies
Block Magnets for HVAC Linear Actuator Production Line
Scaling from 500 to 10,000 pcs/month of N35 block magnets for HVAC damper actuators while reducing unit cost by 18%.
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Magnetic Assembly for Underwater ROV Thruster Coupling
Custom magnetic coupling assembly using N42 NdFeB ring magnets with epoxy coating for subsea ROV thruster applications.
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Spec sheet downloads
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NdFeB spec sheet (reference)
Grades, coatings, and RFQ checklist for NdFeB magnets.
SmCo spec sheet (reference)
High-temperature SmCo summary and RFQ checklist.
Ferrite spec sheet (reference)
Cost-optimized ferrite basics and RFQ checklist.
Alnico spec sheet (reference)
High-temperature Alnico grades and RFQ checklist.
Bonded NdFeB spec sheet (reference)
Bonded NdFeB process notes and RFQ checklist.
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Flexible magnet tape basics and RFQ checklist.
Magnetic assembly spec sheet (reference)
Pot magnet assembly fundamentals and RFQ checklist.
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