In modern industrial applications, the efficiency of permanent magnet synchronous motors (PMSMs) and brushless DC (BLDC) motors hinges on the precise geometry of their core components. Curved segment magnets (often referred to as arc magnets or tile-shaped magnets) are engineered to fit snugly onto the outer diameter of cylindrical rotor cores or within the inner perimeter of stator assemblies. By reducing the physical air gap between the rotor and stator, these highly customized curved profiles optimize the magnetic flux path, significantly increasing magnetic induction and motor torque density.
To withstand the intense mechanical stresses of high-speed rotation and the thermal challenges of continuous industrial workloads, motor rotor designers specify high-coercivity materials such as Sintered Neodymium-Iron-Boron (NdFeB) or Samarium-Cobalt (SmCo). Designing these magnets involves strict calculations around magnetization directions—such as radial alignment, diametrical alignment, or complex Halbach arrays—ensuring the magnetic fields are directed precisely where they yield the maximum electromagnetic force.
A critical challenge in rotor design is secure mechanical containment. As rotors reach speeds exceeding 10,000 RPM, centrifugal force threatens to dislodge permanent magnets. This is where high-strength, non-magnetic, or low-magnetic-interference structural carriers become essential. Advanced aluminum extrusions and structural alloys provide the ultimate solution. Leveraging premium-grade materials from top-tier aluminum extruders, motor manufacturers construct high-rigidity structural sleeves, containment housings, and core frameworks. These structural elements ensure absolute positioning of the curved magnets while keeping weight at an absolute minimum to reduce rotational inertia.
Established in 2015 and located in Foshan City, Guangdong, LvXing Intelligent Equipment Co., Ltd. boasts a skilled R&D team with extensive experience. We leverage exceptional technical expertise to effectively transform customers' ideas into reality, consistently meeting their precise requirements.
We utilize premium Fenglu aluminum, offering a diverse range of profiles for flexible industrial applications. Our advanced extrusion lines, ranging from 800T to 20,000T, accommodate alloys in the 1xxx, 2xxx, 3xxx, 5xxx, 6xxx, and 7xxx series. This allows us to produce shaped structural products with cross-sectional dimensions up to 1.2 meters in width and 28 meters in length. These products are globally recognized for their structural precision and meticulous post-processing, finding broad application in aerospace, military, medical, and specialized industrial sectors.
Our commitment to excellence is evident throughout our manufacturing process, which includes rigorous quality control, secure packaging, and efficient international logistics. This dedication has earned us recognition as a national excellent and honest enterprise, along with quality system certification in accordance with GB/T19001-2016/ISO9001:2015 standards.
Procuring curved magnets for motor rotors requires an understanding of several cost drivers that affect the final pricelist. Sintered Neodymium (NdFeB) price dynamics are influenced by raw material fluctuations of Rare Earth elements (such as Neodymium, Praseodymium, Dysprosium, and Terbium). Dysprosium (Dy) and Terbium (Tb) are added to improve temperature resistance (coercivity) in demanding environments like automotive drivetrains. The higher the thermal rating required (from standard N-grade up to AH-grade, which operates up to 220°C), the higher the raw material cost.
Beyond material grades, the manufacturing complexity of curved surfaces also affects the price. Creating precise radius arcs requires specialized wire-cutting, grinding, and surface coating processes (such as Nickel-Copper-Nickel plating, Epoxy, or Zinc). These steps ensure protection against oxidation without compromising the magnetic circuit's efficiency.
Our machining setups achieve dimensional tolerances within ±0.01mm to ±0.05mm. This minimizes air gaps and limits cogging torque in high-performance applications.
Advanced multi-layer coatings (NiCuNi + Epoxy or Parylene) protect against environmental degradation in marine and offshore applications.
Sourcing materials with high intrinsic coercivity (Hj > 35 kOe) ensures magnetic stability under heavy thermal loads up to 220°C.
In the modern industrial landscape, supply chain resilience is as critical as design efficiency. LvXing's operations in Foshan City, Guangdong, integrate manufacturing and sourcing capabilities that keep global supply chains moving. Our local ecosystem benefits from direct access to raw aluminum refining, automated extrusion tooling, and high-precision CNC post-processing. This vertical integration allows us to produce structural aluminum components and rotor retaining structures with shorter lead times and consistent quality control.
By pairing advanced metalworking with custom permanent magnet sourcing, we help engineering teams worldwide combine structural rotor frames with magnetic profiles. This structural synergy improves assembly efficiency and ensures mechanical stability under extreme rotational stress.
We have officially obtained the prestigious “Special Aluminium Materials for Aerospace” Certificate, verifying our high structural standards.
We utilize premium Fenglu aluminum profiles. With extrusion lines from 800T to 20,000T, we handle alloys in the 1xxx to 7xxx series up to 1.2m wide and 28m long.
Our technical team brings 15 years of industry experience to help identify design issues early and refine ideas into reliable physical products.
Aerospace Special Aluminium Material Authorized Partner
Extrusion alloy range 1xxx to 7xxx series capability
Practical design insights from 15-year experienced engineers
LvXing
