Amazing Magnets Injection Molding 
We produce high-quality injection molded parts with unique over molding capabilities.


Safety:
Loose or dislodged magnets can be dangerous in consumer products, it is important to safely secure the magnets, so they will never pop out.
Talk to one of our experienced design engineers for assistance in selecting the ideal solution for your product. 
Tel.888-727-3327  

Demagnetization:
Magnets will become demagnetized by the high-heat of injection molding. High temperature magnets are available but are more expensive and too brittle for many applications. Amazing Magnets offers a unique post-mold magnetization process that allows our neodymium magnets to be over molded before magnetization. The finished parts are then taken to one of our specialized magnetization machines to be fully charged.



Magnet Integration Options:

Insert Molding    Magnets are embedded into the plastic component.
Over Molding:    Magnets are completely encased in plastic.
Ultrasonic Welding:      2 plastic parts are fused together by localized ultrasonic vibrations.
Other:    Design options for screws, or snap-together components.

 


Insert Molding
Insert Molding is a process where the “unmagnetized” magnet is held inside the mold during injection. This allows the molten plastic to flow around the magnet locking it in place. The entire product is then placed into one of our specialized magnetization machines to be fully charged. 

Holding the magnet during injection:
Molten plastic is injected at high pressure. The magnet must be held securely during this process otherwise it will move during injection. Below are 2 options for holding the magnet during injection.
  Pinch Retainer
The magnet can be held by a series of pins on the mold that surround or “Pinch” the magnet during injection.
When the part is demolded or “removed from the mold”, these pins leave holes in the plastic.
  Pin Retainer
A pin on the mold is inserted to a matching hole in the magnet. Pins holes are usually 2-6mm Dia. depending on the magnet size.
When the part is demolded, the pin is removed from the magnet hole leaving the hole empty.
     

Keeping the magnet secure for daily use:
After insert molding the magnet should be retained by the plastic. This could be a feature in the magnet such as a groove or step, or in the plastic component that surrounds the magnet.  Below are a few commonly used methods for retaining the magnet via insert molding.
    Plastic Cover
The magnet may be partially covered by plastic on both sides to hold it in place.
This feature may be combined with a pinch retainer or pin retainer to hold the magnet during injection.
    Grooved Magnet
A groove is created in the magnet to hold it in place.
This feature may be combined with a pin retainer to hold the magnet during injection.
 
  Stepped Magnet

A step feature is created on the magnet to hold it in place.
This feature may be combined with a pinch retainer or pin retainer to hold the magnet during injection.

    Insert Molded Steel Backer

A steel disc is molded inside the plastic. A fully charged magnet can then be attached to the molded steel disc afterwards in a separate assembly process.

       


Other Magnet Integration Options


Over-Molding
Over-Molding or a "2-shot mold" offers the ability to create fully encapsulated magnets. This is a common requirement when the magnet will be exposed to harsh environments, or in medical applications.

This process involves 2 separate molds. The first mold creates a plastic part with a cavity for the magnet. The magnet is then inserted into the first plastic part. The assembly is then placed into the 2nd mold where the 2nd half of the plastic is injected, covering the magnet and fusing with the first half of the plastic.

 

Ultrasonic Welding
Ultrasonic welding is another way to create fully encapsulated magnets. the part is created as 2 separate pieces. The pieces are then assembled with the magnets and fused together by localized high-frequency vibration.

Snap On
The 2 halves of the plastic component snap together to retain the magnet.

  Screw / Bolt
A countersink, or counterbore feature is created in the magnet. The magnet can then be screwed down. Notches and other asymmetric features can be created in round magnets to prevent unwanted rotation.

  Melt Rivet
A plastic stud can be melted down into a countersunk cavity in the magnet.





 

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