Mixing of Materials:

The process begins with mixing the raw materials:

• Ferrite Powder: This is the magnetic component, typically made from a mixture of iron oxide and either strontium carbonate (SrCO3) or barium carbonate (BaCO3). The specific composition depends on the desired magnetic properties of the final product.
• Binder Material: Synthetic rubber (like polyethene or polypropylene) or plastic (such as PVC) serves as the binder material. This component provides flexibility to the magnet and allows it to be easily shaped.
• Additives: Various additives may be included to enhance properties such as flexibility, durability, and resistance to environmental factors like moisture and heat.

Calendering Process:

Once the materials are thoroughly mixed, they undergo calendering:

• Calendering: The mixed material is passed through calendering rollers. This process helps in achieving a uniform thickness and smooth surface finish for the flexible magnet sheet. The rollers apply pressure to the mixture, compacting it into a thin, flexible sheet.

Magnetization:

After calendering, the magnet sheet undergoes magnetization:

• Magnetization: The flexible magnet sheet is magnetized in the desired orientation. This is typically done by exposing the sheet to a strong magnetic field while it is in a specific position or pattern. This process aligns the magnetic domains within the material, giving the magnet its magnetic polarity and strength.

Cutting and Shaping:

Once magnetized, the flexible magnet sheet can be cut and shaped into various forms:

• Die-Cutting: The magnet sheet is cut into specific shapes and sizes using a die-cutting process. This allows manufacturers to produce magnets in custom shapes tailored to different applications.
• Moulding: In some cases, the magnet sheet may be moulded into more complex shapes using moulds and heat to achieve the desired form.

Surface Treatment:

Depending on the application, the flexible magnets may undergo surface treatments:

• Lamination: The magnet sheet can be laminated with printable surfaces or protective films. This process enhances durability, provides a printable surface for graphics or text, and protects the magnet from wear and tear.

Quality Control:

Throughout the manufacturing process, quality control measures are implemented:

• Testing: The magnets undergo various tests to ensure they meet specific standards for magnetic strength, flexibility, adhesion, and durability.
• Inspection: Visual inspection and dimensional checks are conducted to verify that the magnets meet the required specifications and quality standards.

Application-Specific Customization:

Flexible magnets can be further customized for specific applications:

• Printing: They can be printed with colors, patterns, or text to serve as promotional magnets, educational tools, or decorative items.
• Assembly: Flexible magnets may be integrated into larger assemblies or products, such as magnetic strips for doors or closures, magnetic labels, or flexible magnetic sheets for signage and displays.