Flexible Magnets: Manufacturing, Types, and Applications

Flexible magnets are composite materials made with magnetic elements. They are manufactured by combining rubber-based polymer resin with ferrite powder, then forming the material through extrusion or calendering, followed by magnetization.

Manufacturing Process

In the production of extruded magnetic profiles, the flexible granular material is heated until it begins to melt. It is then forced at high pressure through a hardened die—shaped using electrical discharge machining—to form the desired profile. As the material continuously flows from the die, it is cooled and passed over a magnetizing device, which imparts a bipolar or multipolar magnetic configuration.

Magnetic tapes are produced using a calendering process, where one or two large counter-rotating rollers compress the rubber compound into sheets of uniform thickness. These rollers may be heated or cooled to maintain the required temperature, helping control the compound’s viscosity and flow properties. The resulting sheet thickness is precisely controlled to meet quality standards.

Advantages of Flexible Magnets

Flexible magnets offer a wide range of advantages and applications. They are durable, easy to maintain, and safe for finished surfaces. They contain no oils or plasticizers, which prevents cracking, drying, or surface migration when properly maintained.

They are also safe, being free from lead and barium, making them a non-toxic substrate that is safe for workers and consumers. They are easy to process and can be punched, die-cut, milled, or cut with scissors or a knife for custom applications.

In addition, they offer chemical resistance, with excellent resistance to air, ozone, and steam. They are generally unaffected by most chemicals.

Types of Flexible Magnets

There are several types of flexible magnets on the market, each suited to different applications:

• Plain Magnetic Tape: A basic form of flexible magnet made from a mixture of ferrite powder and rubber polymer. Commonly used in crafts, signage, advertising, mosquito screens, and magnetic accessories.
• Magnetic Strips: Thin, narrow flexible magnets used in applications like refrigerator magnets, magnetic tape, and soft closures. Easily cut into custom shapes and sizes.
• Adhesive Magnetic Tape: Comes with a peel-and-stick adhesive backing, allowing easy attachment to non-magnetic surfaces—perfect for turning non-magnetic objects into magnetic ones.
• Printable Magnetic Sheets: Have a printable surface on one side, allowing direct printing of graphics, text, or images. Popular for custom promotional magnets, educational tools, or decorative items.
• High-Energy Flexible Magnets: Made with more advanced magnetic materials such as neodymium. These offer stronger magnetic properties than standard ferrite-based flexible magnets and are suitable for more demanding applications.
• Magnetic Receptive Materials: These are not magnets themselves but have surfaces that attract magnets. Often used with flexible magnets to create interchangeable, customizable displays.

Conclusion

Flexible magnetic systems have revolutionized many industries by offering efficient, safe, and versatile solutions. From signage to industrial applications, magnets have become essential tools in manufacturing, education, advertising, and infrastructure. Their adaptability and resistance ensure their continued importance across sectors.