Magnet Application Case Studies

Real problems. Real solutions. These examples show how engineers and procurement teams have used Radial Magnets to solve challenging sourcing, quality and magnet-design requirements. Details have been generalized to protect customer confidentiality.

Automotive Wheel Speed Sensor — PPAP-Ready Ring Magnet Supply

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 the drawing, identified tolerance callouts that were driving scrap, produced samples and ran dimensional and magnetic performance testing. We then assembled a PPAP Level 3 package including Process Flow Diagram, PFMEA, Control Plan, MSA Gage R&R and SPC data across an initial production run.

The Result

PPAP was approved on first submission, and the customer established a blanket-order program with scheduled releases. Learn more about our PPAP, traceability and quality support.

Medical Device OEM — Lot-Traceable Disc Magnets

Industry: Medical Devices

The Challenge

A medical device company needed small-diameter disc magnets with consistent pull force and full lot traceability for a controlled design history file. Their procurement team also required shipment-level documentation without an impractically large minimum order.

What We Did

We established a custom SKU to the dimensional and magnetic specification and a documentation workflow supporting lot-specific CoCs, magnetic performance data and regulatory declarations.

The Result

The customer progressed from prototype quantities into production with the required traceability infrastructure. Review available magnet compliance documentation or our medical-device magnet capabilities.

Industrial Robotics — Custom Halbach Array for an End-Effector

Industry: Industrial Automation / Robotics

The Challenge

A robotics systems integrator needed more holding force than standard pot magnets could provide inside a constrained end-effector footprint.

What We Did

Our engineering team worked with the customer’s mechanical requirements to model a custom Halbach-array configuration, produce a prototype and provide pull-force test data before production tooling.

The Result

The prototype exceeded the required holding force by 40%, and the configuration moved into production. Explore our industrial automation and robotics magnet capabilities and engineering tools.

Have a Similar Magnet Application?

If you have a drawing or defined requirements, use the Magnet RFQ Builder. For multiple items or a BOM, use the Bulk Magnet RFQ. If you are still selecting a grade or geometry, start with our Neodymium Magnet Buyer’s Guide.