Applications of Barlog Plastics KEBABLEND M FE 220701/1 PA12 for Plastic Bonded Magnets in Industrial Manufacturing

As a specialty manufacturer of magnetically active polymer compounds, we supply KEBABLEND M FE 220701/1 PA12 to selected industrial leaders for technically demanding downstream sectors. Below, we present detailed application scenarios that reflect the real manufacturing needs, regulatory framework, and formulation strategies deployed by our direct customers in the field of plastic bonded magnets.

1. Automotive Sensor Assembly: ABS Wheel Speed Sensors

Automotive Tier 1 suppliers incorporate our compound to produce plastic bonded magnets for anti-lock braking system (ABS) wheel speed sensors. These magnets enable precise rotational frequency detection even under extreme vibration, temperature fluctuation, and humidity. The polyamide matrix delivers consistent magnetic particle distribution, resistance to brake dust contamination, and withstands continuous under-the-hood exposure.

Industry compliance standards

• IATF 16949 - Automotive Quality Management
• ISO 16750-3 (Road vehicles — Environmental conditions and testing for electrical and electronic equipment — Mechanical loads)
• OEM-specific DVP&R and PPAP requirements (e.g. VW 80000, GM GMW3172)
• REACH Annex XIV and Substances of Very High Concern (SVHC) compliance

Typical usage ratio

• Magnetic filler content: 70–93 wt% (adjusted for desired remanence and coercivity)
• Carrier PA12 content: 7–30 wt% (tuned for injection molding flow properties and mechanical compliance)

Downstream process integration

• High-shear twin-screw extrusion premixes the compound
• Direct injection molding into net-shape sensor inserts
• Overmolding or two-shot molding with encapsulation resin (where increased oil and debris resistance is needed)

Final product types

• Multi-pole magnet rings for ABS sensors
• Encoder magnets for transmission control
• Non-contact speedometer sensor magnets

2. Home Appliance Motor Assemblies: Brushless DC Motor Rotors

Appliance OEMs select our material to create precision rotor magnets for brushless DC (BLDC) motors in washing machines, air conditioning compressors, and refrigerator fans. The PA12 matrix assures dimensional uniformity during injection, essential for achieving correct air gaps and reducing eddy current loss. The optimized ratio of filler to matrix suppresses microcrack formation at elevated motor operation cycles.

Industry compliance standards

• IEC 60335-1 (Household and similar electrical appliances – Safety)
• UL 94 V-0 (Flammability classification for plastic materials)
• EN 60335 (EU appliance directives – electromagnetic compatibility and safety)
• RoHS 2011/65/EU compliance for restricted substances

Typical usage ratio

• Magnetic metal filler: 80–90 wt% (subject to torque and speed requirements of BLDC application)
• Polyamide blend: 10–20 wt% (altered for thermal expansion controls and actuator fit)

Downstream process integration

• Pelletized masterbatch compounded with lubricant additives for improved surface finish
• Injected into magnet segment molds fitted with orientation fixtures
• Rotor assembly through press-fit or in-situ overmolding processes

Final product types

• Segmented BLDC rotor magnets
• Arc-shaped magnet inserts for asynchronous drives
• Miniature fan motor stator magnets

3. Consumer Electronics: Precision Stepper Motor Magnets

Producers of high-precision stepper motors for office automation and personal electronics integrate this compound in the core magnets. The fine magnetic particle distribution allows precise pole definition, essential for the high-resolution angular positioning demanded in inkjet printer carriages, camera autofocus systems, and gaming joystick controllers. Low outgassing PA12 supports cleanroom compatibility.

Industry compliance standards

• IEC 62368-1 (Audio/video, information, and communication technology equipment – Safety)
• IPC-A-610 (Acceptability of Electronic Assemblies)
• RoHS EU 2015/863 compliance
• JEDEC JESD22-A113 (Solderability for electronic assemblies)

Typical usage ratio

• Magnetic alloy loading: 75–88 wt% (varies per desired stepping angle precision)
• PA12 binder: 12–25 wt% (adjusted for miniaturized mold dimensions and magnet adhesion needs)

Downstream process integration

• Micro-compounding in centrifuge-mixing extruders
• Micro-injection molding in precision steel cavity tools
• Automated assembly onto rotor shafts under controlled atmosphere

Final product types

• Bipolar stepper motor magnets
• Micro-rotor torque transmission disks
• Linear actuator magnet strips

4. Industrial Automation: Encoders and Position Sensors

OEMs in the field of automated production equipment utilize PA12-based magnetic compounds to fabricate multi-pole magnet strips and rings for rotary and linear encoders. Consistent isotropic magnetic properties and tight dimensional control contribute to high accuracy in position sensing, even at high-speed cycles on packaging lines, robotics, and conveying equipment. The moisture- and oil-resistant polymer matrix extends device service life in high-throughput environments.

Industry compliance standards

• ISO 13849-1 (Safety of machinery – Safety-related parts of control systems)
• EN 60034-18-41 (Rotating electrical machines – Partial discharge properties)
• CE marking according to relevant EU Machinery Directives
• REACH and RoHS finished good requirements for industrial sensors

Typical usage ratio

• Magnetic filler content: 80–95 wt% (fine-tuned for magnetic field strength and encoder resolution)
• Polyamide percentage: 5–20 wt% (adjusted to reach specific thermal and mechanical targets per device housing)

Downstream process integration

• Batch blending with demolding aids for precise edge definition
• Profile extrusion or strip coextrusion for linear sensor elements
• Ring molding for rotary encoder assemblies using heated cavity systems

Final product types

• Linear scale magnets for positioning sensors
• Rotary encoder multi-pole rings
• Magnetic ruler tapes for feedback systems

5. Power Tool Components: Electric Motor Brush Carrier Magnets

Manufacturers of industrial and DIY power tools mold plastic bonded magnets for electric motor brush carrier subassemblies, using our engineered compound to achieve robust adhesion to metallic laminations and long-term resistance to grease and particulate ingress. The PA12 matrix delivers required flexibility without compromising the retention of magnetic orientation during intensive vibration and heating cycles found in drilling or cutting tool environments.

Industry compliance standards

• IEC 62841-1 (Electric motor-operated hand-held tools, transportable tools and lawn and garden machinery – Safety)
• UL 82, UL 60745 (Electric tools safety)
• RoHS EU 2015/863 for restricted hazardous substances
• REACH SVHC substance list for motor housings

Typical usage ratio

• Total magnetic content: 82–92 wt% (optimized for balance of field strength and carrier toughness)
• Polyamide base resin: 8–18 wt% (adapted for shape stability and assembly line feed rates)

Downstream process integration

• Gravity feeding into injection presses installed in automated tool assembly cells
• In-mold magnetization using pulsed magnetic field systems
• Direct welding or bonding to brush carrier backplates

Final product types

• Magnetic brush carriers for rotary tools
• Magnetized plastic subassemblies for angle grinders
• Commutator magnet inserts for hand-held motor units