Our Process

Total Magnetic Solutions

Bunting-DuBois manufactures prototypes for high volume custom magnets and magnet assemblies. We specialize in providing magnetic solutions through injection and compression molding of Neodymium Iron Boron magnetic materials, as well as other rare-earth magnets. In addition, we stock a large inventory of Neodymium Iron Boron, Samarium Cobalt, Ferrite, Alnico and Flexible magnetic materials. With our extensive knowledge of CNC machining, magnet fabrication and final assembly capabilities, we can meet any magnetic assembly need no matter the complexity. We utilize the latest and leanest technologies applied to assembly processes such as bonding, fastening and potting.

2D and 3D magnetic modeling of your design
Rapid prototyping of designs
Capacity to manufacture magnets and magnetic assemblies in any quantity
Extensive quality checks of product
On-time delivery

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CONSULTING

Engineering and Application Support

Our engineering team complements your design and manufacturing team to develop a permanent magnet or a complete magnetic assembly specific to your need and application. From single assemblies to complete designs, from sensor applications to permanent magnet motors, we have the equipment and skilled personnel to meet any project demands. We collaborate with your team, innovate through world-class design and accommodate with consistent, well-designed, flawlessly manufactured custom products.

Design Consulting Services

Complete engineering, magnetic evaluation and consulting services
Magnetic field mapping
Holding force calculations
Insert and over-molding designs
World-class design and instrumentation equipment
All new assembly development or reverse-engineer to match existing component
Rapid prototype guarantee

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SUPPLY CHAIN

Non-Chinese Supply Chain

The use of rare earth metals is a major factor in determining the cost of magnets and magnetic assemblies. Rare earth materials are mined in a few places around the world. Today 60% of the rare earth elements are mined in China. China manufactures over 80% of the world’s neodymium magnets. The U.S. and China relationship can be summed up as volatile. For its part, Bunting-Dubois continues to seek alternative sources for neodymium, reducing the reliance on China for the commodity.

Manufactured In the U.S.A.
International Traffic in Arms Regulations Registered

Automation

Emerging technologies and automation are essential components in today’s manufacturing economy. The workforce has changed, and sophisticated robotic technology is the difference. Bunting-DuBois invested heavily in game-changing automation for its magnetic assemblies. See some of it in action here.

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Serving Your Industry & Market

Bunting’s experience accumulated through decades of magnetic designs has provided us valuable insight into the changing needs and rigorous demands of our customers. As a result, our engineers have developed a profound understanding of the design and performance of all types of magnetic materials to know which best fits your needs and application.

MANUFACTURING

Custom Magnet Manufacturing

We manufacture custom magnets and custom magnetic assemblies from advanced materials, including, Neodymium, Alnico, Ferrite and Samarium Cobalt. . Injection and compression molding of Neodymium Iron Boron magnetic materials. Our custom magnets are utilized for a multitude of applications across many industries. Our North American facility is ISO 9001:2015 certified, and ITAR registered. We can manufacture as few as 200 or as many as 2,000,000 pieces or more per month. We have the Capacity to manufacture magnets and magnetic assemblies in any quantity.

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Custom Magnets

Custom Magnet Assemblies

Injection Molded Magnets

Neodymium Magnets

Bonded Magnets

Injection Molded Ferrite

NeoBlend™ Molded Neodymium Iron Boron

Sintered Neodymium Iron Boron

Magnets for Motor Assemblies

Magnetic Assembly Capabilities

Precision Machining
Magnetizing
Balancing
Packaging, Stocking and Traceability
Validation and Testing
Rapid Prototypes
Any Quantity – long or short run
Quick Shipment within the U.S. (Pennsylvania-based manufacturing)

Finite Element Analysis

Finite Element Analysis (FEA) modeling programs are used to analyze magnetic problems in order to arrive at solutions, which can then be tested and fine tuned against a prototype of the magnet structure. Using FEA models flux densities, torques, and forces may be calculated. Results can be output in various forms, including plots of vector magnetic potentials, flux density maps, and flux pattern plots. The Design Engineering team at Bunting has extensive experience in many types of magnetic designs and is able to assist in the design and execution of FEA models.

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Rapid Prototyping for Development

We collaborate with your team to create well-designed, flawlessly manufactured permanent magnets and magnetic assemblies specific to the unique needs of your application. We are able to provide rapid prototypes and quick distribution of the final product no matter the complexity. When working with our engineers, you are involved with the design process from start to finish. We have an on-site prototyping facility and our engineers are backed by our world-class manufacturing team, delivering you a product in TWO WEEKS OR LESS. We provide as much application engineering as needed, and allow you to receive more than one prototype at a time if you are configuring multiple designs.

3-D Printing Capabilities

Bunting offers 3D printing, enabling our engineers to efficiently create product prototypes, ultimately saving time and money.

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Fast Distribution

Our location in Pennsylvania means our North American customers receive their goods quicker and at lower freight costs. We can work seamlessly with your lean replenishment programs, employing JIT, Kanban, Dock-to-Stock, etc, to ensure your magnets are available when you need them. While our assortment of equipment and a highly experienced team means you get the product you need for any application, our US location promises fast shipping and lower freight costs from our North American customers. Plus, we can work with you on your lean manufacturing replenishment program (JIT, Kanban, Dock-to-Stock, etc) to ensure your parts are always availabgle when you need them. Optimal customer service and support before, during and after the sale — guaranteed.

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