Insert-molded and encapsulated magnetic components integrating permanent magnets, polymer, shaft or carrier into a protected production-ready part.
Mechanical interlocks and encapsulation are designed so magnetic insert retention does not depend only on adhesive.
Chemical exposure, temperature and dimensional stability drive the resin choice.
Mold filling can shift inserts or affect fiber orientation and critical datums.
Tooling compensation and measurement plan are defined before volume release.
| Design item | Options / variables | Why it matters |
|---|---|---|
| Magnet | Bonded NdFeB, sintered NdFeB, SmCo, ferrite | Temperature, field, coating and molding exposure |
| Polymer | PA6/66, PPO, PPS, PEEK, TPE or project-specific | Temperature, chemical resistance, molding window |
| Mechanical lock | Shoulders, holes, ribs, undercuts | Reduces dependence on adhesion alone |
| Gate / flow | Gate location and flow direction | Controls insert movement and weld-line risk |
| Wall / ribs | Uniform wall with structural ribs | Controls shrinkage, sink and warpage |
| Sealing | Geometry and material system | Validated to the actual leakage / ingress requirement |
| Application / Architecture | Typical Configuration | Engineering Focus |
|---|---|---|
| Wet-rotor pump | Magnet + stainless shaft + PPS/PEEK overmold | Sealing, chemical compatibility, runout |
| Sensor rotor / target | Magnet insert + molded carrier | Pole location, dimensional datums, material stability |
| Motor ring / hub | Bonded/sintered magnet + polymer carrier | Retention, multipole magnetization, balance |
| Sealed actuator | Rare-earth magnet encapsulated in polymer | Environmental protection and repeatability |
| Parameter | Capability / Options | Notes |
|---|---|---|
| Polymer options | PA6/PA66, PPO, PPS, PEEK, TPE | Selected by temperature, media and mechanical load |
| Magnet options | Bonded NdFeB, coated sintered NdFeB, SmCo, ferrite | Material and coating depend on exposure and molding route |
| Part size | Up to ~150 mm class on existing reference programs | Final moldability depends on geometry |
| Molded tolerance | ±0.05 mm class typical on critical molded features | Tooling and material shrinkage considered |
| Temperature | PA ~120°C / PPS ~180°C / PEEK higher by project | Actual system temperature depends on magnet + polymer + media |
| Sealing | Project-specific IP / hermeticity target | Validated by agreed leak / immersion test |
Magnet / shaft / carrier dimensions and surfaces verified
Magnetic insert held in mold with controlled orientation
Process window controls pressure, temperature and fill
Dimensions, flash, voids, insert position
Pole pattern, flux, leak or functional checks per project
Critical molded datums and insert position measured to agreed plan.
Flux / pole pattern checked after molding if process could influence field.
Pressure, immersion or customer-defined method where sealing is functional.
Pre-shipment video can show live dimensional / functional testing for customer verification.
| RFQ / DFM input | What to provide |
|---|---|
| 3D model / drawing | Magnet, insert, polymer, wall thickness and datums |
| Media / environment | Fluid, chemicals, humidity, temperature |
| Functional requirement | Sealing, torque, field, sensor threshold, mechanical load |
| Tooling requirements | Expected life, annual volume, cavitation / gate constraints |
| Validation | Leak, dimensional, magnetic, aging / thermal requirements |
PPS and PEEK are common when temperature or chemical resistance is demanding; PA/PPO can be more economical. Selection is project-specific.
Yes, but coating, molding temperature, pressure and insert retention need to be reviewed carefully.
We can develop overmolded magnetic components for sealed environments; the leak/IP target and test method must be defined in the project.
Uniform walls around 1.5–3 mm are often easier to mold, but the correct thickness depends on resin, geometry and structural needs.
We can review magnets, mechanical retention, interfaces, magnetization, inspection and supply as one program.
Verify magnet/metal insert dimensions, coating and polarity state.
Locate inserts and control magnetic attraction during loading.
Set material-specific melt/mold temperatures and cycle conditions.
Validate molded datums and adjust tooling/process as needed.
Magnetize before or after molding as the design requires; verify functional output.
Dimension, sealing, appearance and magnetic function to project requirements.
Critical molded interfaces and datums.
Pole / field / functional performance after molding.
Leak or ingress test where specified by the product design.
Remote verification of final dimensions, magnetic function or sealing test where practical.
