Real problems. Real solutions. Here’s a look at how engineers and procurement teams have used Radial Magnets to solve challenging magnet applications. Details have been generalized to protect customer confidentiality.
Industry: Automotive / Tier 2 Supplier
The Challenge
A Tier 2 sensor manufacturer needed a reliable source for N42 ring magnets for ABS wheel speed sensor assemblies. Their previous supplier had inconsistent dimensional tolerances, causing field failures in sensor output at temperature extremes. They also needed a full PPAP Level 3 submission to qualify a new supplier with their Tier 1 customer.
What We Did
We reviewed their existing drawing and identified two tolerance callouts that were driving scrap rate at the previous supplier. After recommending a minor adjustment to the OD tolerance (from ±0.001″ to ±0.002″ in the less critical axis), we produced sample parts and ran dimensional and magnetic performance testing. We then assembled a complete PPAP Level 3 package including Process Flow Diagram, PFMEA, Control Plan, MSA Gage R&R study, and SPC data across an initial production run of 500 pieces.
The Result
PPAP approved on first submission. The customer moved their full production volume to Radial Magnets and established a blanket order program with quarterly releases.
Industry: Medical Devices
The Challenge
A medical device company developing a wearable drug delivery system needed small-diameter disc magnets with consistent pull force and full lot traceability for their design history file. Their procurement team had struggled to find a supplier willing to provide certificate-of-conformance documentation at the lot level without a minimum order in the tens of thousands of pieces.
What We Did
We established a custom SKU for their part, sourced to their dimensional and magnetic spec, and set up a documentation workflow that automatically generates a lot-specific CoC, magnetic performance data sheet, and RoHS declaration with each shipment. We also provided conflict minerals disclosure documentation for their DHF.
The Result
The customer now orders on a per-project basis with full documentation, starting from prototype quantities through initial production. The traceability infrastructure we built for them has already passed two external quality audits.
Industry: Industrial Automation / Robotics
The Challenge
A robotics systems integrator was designing a magnetic end-effector for handling ferrous sheet metal in a press-stamping line. Standard pot magnets weren’t generating enough holding force in the available footprint, and the customer needed a compact, high-field design. They had no prior experience with Halbach arrays.
What We Did
Our engineering team worked with their mechanical engineer to model the field strength and holding force of a custom Halbach array configuration within the space envelope. We produced a prototype array and provided pull-force test data before they committed to tooling their mounting structure.
The Result
The prototype exceeded the required holding force by 40%. The integrator moved to production on the Halbach array design and has since incorporated the same configuration into two follow-on product lines.