Magnet processing, or magnet manufacturing, involves transforming raw magnetic materials into a finished, usable form. The specific techniques vary drastically depending on the magnet material. For sintered Neodymium (NdFeB) or Ferrite (Ceramic) magnets, the process involves finely powdering the raw materials, pressing them in a die within a powerful magnetic field (to align the particles), and then sintering them at high temperatures to fuse the powder into a solid, dense magnet. This is followed by grinding to achieve precise dimensions and then coating to prevent corrosion.

For other types, the process differs. Bonded magnets are made by mixing magnetic powder with a polymer binder (like rubber or plastic) and then forming them through injection molding, extrusion, or calendaring. This allows for complex shapes and flexible magnets. Cast Alnico magnets are produced by pouring molten metal into sand or shell molds, making them suitable for intricate designs and high-temperature stability. After the primary forming, nearly all magnets undergo secondary processing, such as precise slicing with wire EDMs, grinding, or drilling, to meet tight tolerances that cannot be achieved in the initial pressing or casting stage.

The chosen processing method directly defines the magnet's key characteristics: its geometry, dimensional accuracy, magnetic orientation, and ultimate strength. Sintering produces the strongest permanent magnets but with shape limitations, while bonding allows for great geometric freedom at the cost of magnetic strength. Understanding these trade-offs is essential for selecting the right manufacturing route to produce a magnet that is not only powerful but also possesses the correct physical form and durability for its intended application.