Custom Magnetic Design & Engineering

At Dura Magnetics, you get the best magnet and magnetic assembly design and engineering assistance in the marketplace. We combine our accumulated knowledge and experience with new innovations and technology. Magnetic assemblies and magnet solutions are engineered to order using 2D and 3D magnetic simulation packages for a wide variety of applications, such as medical devices, senor triggering, electromechanical devices, and more.

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Concept Validation

We are committed to using technology and design to ensure the manufacturability of your magnetic requests, because we understand that our customers are not always certain about the existence or feasibility of a magnetic solution.

Dura leverages its technical assets, including computer simulations with 2D and 3D FEA and boundary analysis software to validate design concepts. This helps to reduce product development time and expense, while ensuring manufacturability of the finished product. By utilizing simulation software, a tentative solution can be generated, forwarded, and discussed with your design team. After preliminary models are reviewed, an informed decision can then be made on how or whether to proceed.

Reverse Engineering

Dura’s industry expertise and in-house capabilities allow us to reverse engineer an existing magnet or magnetic assembly to improve performance, enhance service life, quantify and qualify older designs, and reduce costs.

These capabilities include:

  • Hysteresis Graph to Quantify Magnetic Characteristics
  • Simulation and Modeling
  • Performance Benchmarking
  • Chemical Analysis

Overcoming Challenges with Custom Solutions

During the design phase of your project, it is important to consider the complexities associated with using magnetic materials. Both the magnetic performance and how the magnet will be integrated into the final solution are important.

Magnetic materials, unlike common commercial materials that have ASTM classifications, are difficult to manufacture and fabricate; they present a special set of challenges. Therefore, it is necessary for the design team to take special care when creating a custom solution for your application.

  • Oxidizing or reactive environments
    Magnetic materials are typically environmentally unstable. They can be highly reactive and prone to oxidation. Common coating and plating solutions usually do not translate to magnetic alloy.

  • Temperature flucutations
    Magnetic materials gain or lose magnetic field relative to the operational temperature fluctuations. The design must take into account magnetic performance through a temperature spectrum.

  • Extreme temperture
    These materials can experience irreparable harm at extreme temperature exposures. This harm is irrecoverable and represents an effective partial or total demagnetization of the magnet.

  • Difficulty machining magnetic material
    Because conventional machine tools and machining methods are not feasible, magnets can be challenging to fabricate.

  • Non-linear magnetic force
    They can also be challenging to design, since the magnetic field density and resulting force are not linear relative to distance.

  • Integration and retention
    Common methods of component integration and retention such as tapped holes, shoulders, through holes, staking, and tapers are expensive to employ. The integration of a magnet into a sub-assembly requires a functional knowledge base when designing an integration scheme.

  • Magnitized
    Magnetic materials are magnetized. This seems obvious, but magnetized magnets and sub-assemblies present a unique set handling and integration problems. Issues can range from protecting the operators to demagnetizing of the magnet itself. This aspect must be accounted for early in the design phase.

  • Unlike common materials
    Commonly requested specifications attributed to conventional materials—such as aluminum, steel alloys, and plastic—are usually challenging to implement with magnets and magnetic materials. These specifications, usually indicated on a drawing by default, may add cost and complexity when manufacturing a magnet or magnetic assembly. It is important to review the relevance of these industry standard features and specifications when designing and specifying a magnet or magnetic assembly.

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Optimization for Performance, Cost, & Price Volatility

Magnet alloy is often the most expensive part of an assembly. By optimizing a magnet design for an application using simulation software, Dura Magnetics can significantly reduce the cost.

Relative to common commercial materials such as steel, aluminum, and plastic resins, the volume of magnet alloy manufactured in the world is quite low. Because of the low magnetic alloy production levels and small number of mines, refinery operations, and mills, price volatility is quite common. Using an engineering-oriented approach to design, Dura Magnetics can optimize the magnet for your application’s specific product, reducing your exposure to price volatility.

Trusted to meet your regulatory needs

  • DFAR Specialty Metals Clause 252.225.7009
  • Export Controlled Item
  • Conflict Minerals Section 1502 Dodd-Frank
  • REACH RoHS – RoHS 2

We focus on quality

  • AS9100D certified
  • MIL-SPEC 45208A tolerances
  • Coordinate measurement machines and video inspection system
  • In-house testing of field density and field strength
  • Hysteresis graph for magnetic characteristic measurement

Engineering & Product Development Specialists

Are you frustrated because potential vendors are not effectively communicating the nuances of a design or fabrication process? Or have you grown weary of hearing your application is too simple or too technically complex? Then perhaps it is time to consider Dura. We are an engineering-oriented company that has the willingness and ability to understand industry, segment, language, and unique specifications.

Unlike some magnet design manufacturers that limit access to design and engineering staff, Dura understands that communication is key to your project’s success. Our design and engineering team members remain engaged throughout the life of your project to ensure that a knowledgeable professional is always available. Whether your project’s scope ranges from prototype development to production quantity runs, we welcome your magnet or magnetic assembly challenges and the opportunity to provide you with best-in-industry solutions.

Contact us to get started on your next project.

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Next Step:

Custom Magnet Manufacturing

Once we’ve overcome any challenges in designing and engineering your magnet or magnetic assembly, it’s time for manufacturing.

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