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US-Made Injection Molded Magnets

Achieve Geometric Precision and Secure Your Supply Chain

We engineer and mold high-precision magnetic components, helping you optimize performance and guarantee production stability.

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Standard Magnets Limit Your Innovation.

You’re redefining performance in sensor accuracy and motor design, but outdated magnet manufacturing methods are holding you back.

Design Constraints
Sintered magnets chip, crack, and cannot achieve the complex shapes your new design requires.  
Assembly Costs
Glued assemblies are inconsistent and labor-intensive, driving up your total cost of ownership  
Supply Risk
Relying on overseas supply chains leaves your production line vulnerable to tariffs, export bans, and shipping delays.
  

Every day you rely on standard components, you face greater risk of costly downtime, from export delays to field failures caused by assembly defects.

Total Design Freedom. Zero Assembly Compromise.

Our injection molded magnets are formed unmagnetized, then precisely magnetized to your required orientation and pole pattern. With integrated magnetizing systems and components, Magnet Applications delivers a complete end‑to‑end solution, whether in‑house or at your facility.

Complex Geometry & Multi-Pole Magnetization

Benefit: Create intricate shapes with tight tolerances that sintered magnets simply cannot match.

Result: Maximum Performance: Achieve more compact motor and sensor designs with optimized packaging, seamless assembly integration, and precise magnetic field control.

  
Insert & Over-Molding Capabilities

Benefit: We mold the magnet directly onto the shaft or into the housing, eliminating adhesives and assembly steps.

Result: Reduced Cost & Higher Durability: Simplify assembly and strengthen mechanical integrity for reliable performance in demanding, high‑speed applications.

  
Domestic Manufacturing

Benefit: Complete engineering, tooling, and production located in DuBois, PA.

Result: Supply Chain Security: Predictable lead times and immunity to global trade volatility.

  
Tailored Magnetic Materials

Benefit: Custom blends of NdFeB, Ferrite, or Hybrid materials with Nylon or PPS binders.

Result: Specific Application Fit: Engineered material formulations optimized for superior magnetic performance, mechanical strength, and environmental durability.

  

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We Are More Than A Manufacturer. We Are Your Engineering Partner.

You’re under pressure to launch a flawless product fast. For over 40 years, Magnet Applications, a Division of Bunting, has been one of North America’s few true injection molders of magnetic materials. We partner early in your process to refine the design before the mold is ever cut.

Challenge

A customer needed a complex 6-pole radial magnetic field for a coupling but faced high assembly costs. 

  
Solution

Our engineers developed a unique bonded assembly magnetised after injection molding. 

  
Outcome
Manufacturing costs reduced by 90% with zero compromise in torque ratio.  

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From Concept to Production in 3 Simple Steps.

1
Engineering Consultation
 Connect with our team early. We review your STEP files, optimize geometry for molding, and run 2D/3D field models to validate performance. 
2
Prototyping & Validation
We design the mold and magnetizing fixtures in-house, delivering prototypes for your validation testing.
3
Scale & Secure
 We ramp to high-volume production and secure your inventory with our MagVault stocking agreements, ensuring you never run out of parts. 

Engineered Materials for Every Environment.

Material Type Best For Binder Options Key Characteristic
Neo-Nylon High-performance sensors & motors Nylon 6 / 12 Highest strength injection molded material.
Ferrite-Nylon Cost-sensitive, high-volume apps Nylon 6 / 12 Excellent corrosion resistance & low cost.
Hybrid Tuning performance & cost Nylon / PPS Blends properties of Neo and Ferrite.
PPS Blends Harsh, high-temp environments PPS Resists chemicals and high heat (automotive).

Stop Wrestling with Fragile Magnets and Unreliable Supply Chains.

At Magnet Applications, we know that you want to be the innovator who delivers a robust, high-performance product on time. In order to do that, you need a magnetic solution that offers geometric freedom and supply chain security. The problem is that standard sintered magnets restrict your designs and rely on volatile overseas supply chains, which leaves you worried about field failures and line stoppages. We believe engineers shouldn't have to fight their components to get a product that works.

We understand the complexity of integrating magnets into compact devices, which is why for over 40 years we have been the North American leader in bonded magnet technology. Here is how we do it: We engage in collaborative engineering to optimize your design, we utilize precision injection molding to create complex geometries right here in the USA, and we secure your supply with long-term stocking agreements. Discuss your project with us today so you can stop worrying about broken magnets and missed shipments, and instead launch your product with total confidence.

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Frequently Asked Questions

Can injection molded magnets match the strength of sintered magnets? While injection molded magnets typically have lower magnetic energy products than fully dense sintered magnets, they offer superior net-shape capabilities and multi-pole magnetization patterns that can actually result in higher total system performance for sensors and motors. 
What are your typical lead times? Because we manufacture in DuBois, PA, our lead times are significantly shorter and more consistent than overseas competitors. We also offer MagVault stocking agreements to guarantee instant availability for recurring orders.
Do you handle the magnetizing fixtures? Yes. We design and build custom magnetizing fixtures in-house to ensure the magnetization pattern perfectly matches your specific sensor or motor requirements. 
Can you over-mold magnets onto shafts? Yes. Insert molding is a core capability. We can mold magnetic material directly onto shafts, stators, or other substrates, reducing your assembly time and improving component concentricity. 

Get Started Today

Let's work together to scale your manufacturing.
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