The first step in magnet manufacturing is selecting and preparing the raw materials. In the case of neodymium magnets, rare earth elements such as neodymium, iron, and boron are combined in specific ratios. These materials are typically mined and refined before being mixed into a fine powder. In ferrite magnets, the mixture usually consists of iron oxide and either barium carbonate or strontium carbonate. The raw materials must be carefully weighed, blended, and milled to ensure uniform composition.

Once the raw material mixture is ready, it is formed into a desired shape using various molding methods. One common technique is pressing the powder in a mold using a high-pressure hydraulic press. This compacts the powder into a "green" compact, which holds its shape but is still fragile. At this stage, magnets can be aligned in a magnetic field to orient the particles and enhance their magnetic properties. This process is known as anisotropic pressing. If no alignment field is used, the result is an isotropic magnet, which is generally weaker but easier to manufacture.

After pressing, the green magnets undergo a sintering process. Sintering involves heating the compacted material in a controlled atmosphere Welding Magnets at high temperatures, typically between 1000°C and 1200°C, depending on the material. This causes the particles to fuse together and creates a dense, solid structure. During sintering, the magnet’s microstructure develops, which has a direct impact on its final magnetic performance. In the case of neodymium magnets, sintering is a critical step that helps achieve the strong magnetic properties for which they are known.

Following sintering, the magnets are cooled and then machined to precise dimensions. Sintered magnets can be very hard and brittle, so diamond-coated grinding tools or wire electrical discharge machining (EDM) are used to shape them accurately. Tight tolerances are essential in many applications, especially in electronics and motors. After machining, the magnets may be coated or plated with materials like nickel, zinc, epoxy, or gold to prevent corrosion and mechanical damage. This is especially important for neodymium magnets, which are highly susceptible to oxidation if not protected.