How to Select the Right Neodymium Magnet Grade (Without Over‑Engineering)

by Shaunmarie Gutbezahl | May 27, 2026 | Allstar Magnetics News, Industry News, Products

Neodymium (NdFeB) magnets offer unmatched magnetic strength, but selecting the right grade is more complex than simply choosing the highest energy product available. Many designs fail not because the magnet is too weak—but because it was over‑specified in the wrong direction.

Start with operating conditions, not peak strength.

Standard NdFeB grades perform well up to ~80°C. If your application experiences higher continuous temperatures, thermal suffix grades (H, SH, UH, EH) become essential. Insufficient coercivity at temperature can lead to irreversible demagnetization—even if the magnet initially met performance targets.

Balance magnetic output with coercivity margin.

High energy product grades like N52 deliver impressive strength, but lower‑energy grades with higher coercivity often outperform them in motors, actuators, and high‑load environments. The goal is stable performance over the product’s full lifecycle—not maximum force on day one.

Consider supply‑chain resilience early.

Higher coercivity grades often rely on heavy rare earth elements (HREs) such as dysprosium or terbium. Where operating conditions allow, HRE‑free grades can reduce cost volatility and sourcing risk without sacrificing performance.

Think system‑level, not component‑level.

Air gaps, steel flux paths, magnet geometry, and tolerances all influence real‑world magnetic output more than datasheet values alone.

Key takeaway:

The “right” neodymium magnet is the one that maintains performance under real operating conditions—not the one with the highest nominal strength.

NEODYMIUM PAGE

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Engineers In Action

by Shaunmarie Gutbezahl | Apr 14, 2026 | Allstar Magnetics News, Industry News

Smarter Magnetic Mapping: A Custom Tool That Delivers Repeatability and Flexibility

At Allstar Magnetics, we don’t believe in one-size-fits-all solutions—especially when it comes to magnetic field mapping. A recent project required us to measure the magnetic fields inside long tubes with magnets—a task complicated by the distance normally needed between the probe and the part. Traditional mapping tools would have required a large setup, extra space, and significant cost. Instead, one of our engineers developed a unique, custom mapping method. By designing a specialized fixture that allowed us to place the probe exactly where needed, we eliminated the distance barrier that usually makes this kind of measurement difficult. The result was a tool that is:

Repeatable – Delivers reliable measurements, time after time.
Flexible – Can be adapted quickly for different part configurations.
Efficient – Saves space and cost compared to traditional mapping systems.

Because this custom solution is both precise and replicable, it streamlines the measuring process not just for this project, but for future projects as well. This innovation is a clear example of how Allstar engineers listen, innovate, and deliver smarter tools that help our customers move faster, with more reliability, and often at a lower cost. When standard tools fall short, the right solution often starts with a technical conversation. If you’re facing a measurement or mapping challenge that doesn’t fit off-the-shelf methods, let’s talk through it together.

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When off-the-shelf isn’t an option, precision makes the difference

by Shaunmarie Gutbezahl | Apr 14, 2026 | Newsletters

April 2026: Issue 8

When off-the-shelf isn’t an option, precision makes the difference

A leading equipment manufacturer came to Allstar Magnetics with a problem most suppliers couldn't solve: they needed a ferrite UCore larger than anything available off the shelf — without sacrificing dimensional precision, structural integrity, or cost-effectiveness.

The answer wasn't a bigger part. It was a smarter process. Through precision gluing of ferrite sections, expert adhesive selection, and custom fixturing, Allstar engineered a bonded UCore assembly that met every requirement — and opened the door to a growing engineering partnership.

"What began as a single design challenge has since expanded — the customer is now exploring additional ferrite core variations and future applications built on the same bonded core approach."

Read the full case study

Sometimes the best tool is the one you build yourself.

Mapping magnetic fields inside long tubes sounds straight forward until you factor in probe placement, spatial constraints, and the cost of traditional setups that simply weren't designed for the job.

Rather than work around the limitations, an Allstar engineer designed a custom fixture from scratch—one that places the probe exactly where it needs to be, delivers repeatable results, and adapts quickly across different part configurations. It's the kind of solution that makes the current project easier and every future project faster.

Read the article

Tighter tolerances, bigger runs—we just leveled up.

Allstar just added a Chevalier H818ii CNC Surface Grinder to our production floor, and we're not going to pretend we're not excited about it. This machine holds positioning and repeatability accuracy to 0.0001". That's not a typo. That's four decimal places of precision—running overnight, running weekends, running without operator intervention.

For our customers, that means high-volume magnet grinding with the kind of consistency that used to require a lot more time, cost, and crossed fingers. Tight tolerances. Significant stock removal. No variability from manual input. Just the program, the part, and the result you need.

Got a high-volume order that demands tight tolerances? Parts with serious stock removal? This machine was built for exactly that—and we're ready to put it to work for you.

Let's talk about your next order

A CASE STUDY: PRECISION GLUING UNLOCKS LARGER, COST-EFFICIENT ASSEMBLIES

by Shaunmarie Gutbezahl | Mar 26, 2026 | Allstar Magnetics News, Case Study

Client:

Leading Equipment Manufacturer

The Challenge:

A leading equipment manufacturer required a large ferrite U-Core to support a critical piece of equipment. Standard off the shelf ferrite core options couldn’t meet the project’s requirements for size, geometry and dimensional precision. Custom performance was essential, but the solution also needed to be precise, manufacturable, scalable and cost effective.

The challenge centered on producing a ferrite U Core beyond conventional size limits while maintaining tight tolerances, structural integrity, and repeatable quality.

Prototyping and Validation

To reduce risk and validate the approach, Allstar recommended a focused prototype run. This allowed the customer to evaluate mechanical fit, dimensional accuracy and real world performance of the large ferrite U Core within their system.

The prototype met all technical and quality requirements, confirming that the bonded ferrite approach successfully addressed the limitations of off the shelf components.

Results

With prototype validation complete, the project transitioned smoothly into production. The custom ferrite U Core solution delivered the required size and precision while remaining cost effective and scalable.

What began as a single design challenge has since expanded. With confidence in the manufacturing process, the customer is now exploring additional ferrite core variations and future applications built on the same bonded core approach—strengthening an ongoing engineering partnership.

Comprehensive magnetic solutions, all in one place.

Why Custom Ferrite Gluing—and Why Allstar

When standard ferrite components reach their practical limits, precision gluing of ferrite cores enables new design possibilities. Bonding ferrite sections into a unified U-Core assembly allows for larger geometries without sacrificing performance or manufacturability.

However, gluing ferrite is not a simple extension of standard processes. Ferrite’s porous structure, brittleness and sensitivity to alignment demand specialized knowledge in adhesive selection, surface preparation, fixturing, and process control.

Allstar Magnetics brings deep expertise in ferrite material behavior and bonded core assemblies, supported by years of research and development and production experience. This capability allowed Allstar Magnetics to address the customer’s design constraints without compromising long term reliability or production efficiency.

The Collaborative Solution

Allstar partnered closely with the customer’s engineering team to co develop a custom ferrite U Core solution. The process began with a detailed review of drawings and functional requirements, followed by design refinements focused on manufacturability.

Adhesives were carefully selected to ensure compatibility with ferrite materials, promoting strong bonds while maintaining clean interfaces and dimensional stability. Custom fixturing and alignment methods were developed to ensure precise geometry across the bonded U Core assembly, enabling consistent results from prototype through production.

Throughout development, Allstar emphasized repeatability, yield and scalability—ensuring the solution would perform not only in validation testing, but also in full scale manufacturing.

The Allstar Advantage

Allstar Magnetics’ advantage lies not only in producing custom ferrite assemblies, but in how those solutions are engineered. Every project begins with a manufacturing first mindset, balancing performance requirements with precision, repeatability and cost control from day one.

By combining deep ferrite material expertise with disciplined process development, Allstar delivers bonded ferrite U Core assemblies that move reliably from concept to production—eliminating the compromises often associated with oversized or non standard core designs.

Looking Ahead

Allstar and this leading equipment manufacturer continue to build on this success, developing new ferrite core configurations that push beyond standard catalog limitations while maintaining production ready quality. Together, they are unlocking larger, more capable ferrite solutions designed for today’s demanding equipment applications.

Ready to power your next breakthrough?

Contact Allstar Magnetics to discover how our turnkey approach can simplify your supply chain and deliver the results your team needs to succeed.

contact us

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Designing for Heat? Here’s What You Need to Know About High-Temperature Neodymium

by Shaunmarie Gutbezahl | Mar 18, 2026 | Newsletters

March 2026: Issue 7

Designing for Heat? Here’s What You Need to Know About High-Temperature Neodymium

By Bill Evers, Sales - Permanent Magnets (East) Bill Evers - Sales Permanent Magnets (East)

As material restrictions tighten and sourcing realities shift, designing with high-temperature neodymium magnets has become more complicated than ever. From UH-grade performance requirements to HRE-free material availability, engineering teams are navigating a fast-changing landscape.

In this month’s newsletter, we break down what’s currently available, how temperature ratings impact performance, and how Allstar helps teams design around restrictions—without sacrificing reliability or manufacturability.

▶ Read The Full Article HERE

The Allstar Magnetics team is heading to APEC 2026 (Applied Power Electronics Conference), March 22–26 in San Antonio, Texas. APEC brings together engineers, designers, and manufacturers from across the power electronics industry to share ideas, explore new technologies, and talk about the challenges shaping tomorrow’s designs.

If you’ll be attending, stop by Booth #205 and say hello. Our team would love to connect, learn about what you’re working on, and talk about how Allstar supports customers from early design and prototyping through scalable manufacturing.

Want to make the most of your time at APEC? Reach out now to schedule a dedicated meeting with our team at the show. sales@allstarmagnetics.com