Permanent Magnets (PM) play a crucial role in countless industrial applications, ranging from automation and robotics to energy, mobility, and precision manufacturing. Yet their impact is often underestimated or considered only late in the design process. To fully leverage the potential of magnetic PM technology, magnets should be treated as a full-fledged engineering component rather than a last-minute addition.
Below, we outline three core principles for effectively integrating magnets into your production processes while ensuring long-term performance, reliability, and cost efficiency.
1. Involve magnet specialists early in the design phase
The performance of a Permanent Magnetic solution is largely determined during the design phase. Factors such as magnet material selection, geometry, tolerances, operating temperature, environmental influences, and interaction with surrounding components all directly affect the final outcome.
Key parameters include:
- Material selection (NdFeB, SmCo, ferrite, AlNiCo) in relation to force, temperature, and stability
- Magnetic geometry and field distribution (axial/radial, open vs. closed magnetic circuits)
- Air gap specifications and tolerance chains
- Influence of surrounding materials, such as ferromagnetic structural components
- Temperature and demagnetization margins (operating point on the B-H curve)
By involving magnet specialists early on, you can:
- select the right magnet type and grade for your application
- avoid over-dimensioning or under-dimensioning magnetic force
- reduce redesigns, delays, and unexpected costs later in the project
Early collaboration ensures that magnetic functionality aligns seamlessly with mechanical, electrical, and production requirements.
2. Test prototypes under realistic operating conditions
Theoretical magnetic behavior does not always translate directly into real-world performance. External influences such as vibration, heat, contamination, mechanical loads, and assembly tolerances can significantly affect results.
That is why prototype testing is essential. By evaluating magnets under realistic operating conditions before scaling up to series production, you can:
- validate performance and safety margins
- identify risks early and optimize the design
- ensure repeatability and production robustness
Prototyping minimizes surprises and increases confidence in long-term performance.
3. Plan for maintenance and lifecycle performance
Although magnets are often considered “maintenance-free,” their performance can degrade over time due to wear, corrosion, demagnetization, or changing operating conditions.
A proactive maintenance strategy helps to:
- maintain consistent performance throughout the entire lifecycle
- prevent unexpected downtime or failures
- extend the lifespan of magnetic assemblies
Regular inspections and performance checks ensure that your magnetic solution continues to operate reliably year after year.
From component to competitive advantage
When Permanent Magnets are properly integrated, they do more than support a process, they enable smarter designs, reduce mechanical complexity, improve energy efficiency, and enhance overall system reliability.
Our engineers and specialists at Bakker Magnetics support you in translating magnetic theory into robust industrial solutions. From material selection and simulation to prototyping and series production, we work with you to optimize performance, mitigate risks, and refine designs.
Feel free to contact Bakker Magnetics to discuss your current or future projects. We are happy to help make them more effective, cost-efficient, and innovative.
