Manufacturing special shaped sintered NdFeB magnets starts with jet‑milled powder. This powder is pressed in a die to form green special shaped sintered NdFeB magnets. A magnetic field is applied during pressing to orient the crystals.

The green compacts of special shaped sintered NdFeB magnets are sintered at 1050°C. After sintering, special shaped sintered NdFeB magnets are machined with diamond wheels. The slicing of special shaped sintered NdFeB magnets uses wire EDM for complex shapes.

Special shaped sintered NdFeB magnets with a hole are drilled with a diamond core bit. The surface of special shaped sintered NdFeB magnets is ground to final dimension. Special shaped sintered NdFeB magnets are then coated in a barrel‑plating machine.

A typical run of special shaped sintered NdFeB magnets yields 10,000 pieces per batch. The reject rate for special shaped sintered NdFeB magnets is 3% due to cracking. The orientation of special shaped sintered NdFeB magnets is checked with a fluxmeter.

Special shaped sintered NdFeB magnets with a multi‑pole pattern require a special magnetizing fixture. The magnetizer discharges 3,000 volts to saturate special shaped sintered NdFeB magnets. After magnetization, special shaped sintered NdFeB magnets are shipped in a shielded box.

The hardness of special shaped sintered NdFeB magnets is 65 HRC, making them brittle. Special shaped sintered NdFeB magnets with a sharp corner are prone to chipping. A chamfer on special shaped sintered NdFeB magnets reduces edge fracture during handling. The future of special shaped sintered NdFeB magnets includes additive manufacturing of near‑net shapes.