MAGNETS

High-Performance Magnets. Manufactured for Resilience.

CAPABILITY

The platform for reindustrialization

Neodymium iron boron permanent rare earth magnets power the world’s most important technologies. They convert electricity into motion, enabling everything from semiconductors, AI infrastructure, and automobiles to satellites, aerospace systems, robotics, drones, and virtually all defense applications. Vulcan is the platform for the industrial future as our world becomes more advanced and electrified.

Best-in-class magnets

Vulcan’s production process is designed to maximize quality and durability. Our expansive range of in-spec grades produced reflects technical maturity across materials science, engineering, and manufacturing, enabling us to satisfy a broad range of performance requirements for commercial and national security applications.

Unparalleled security & resilience

Vulcan’s process, magnets, and supply chain are decoupled from all Foreign Entities of Concern, down to the material, technology, IP, software and ownership–ensuring that our process, product, and customers can withstand international supply disruptions.

Engineering-driven partnerships

Vulcan’s responsibility to customers goes beyond fulfilling contracts. Our commercial team works in lockstep with customers to define and optimize requirements to guarantee performance and maximize efficiency. Every member of the team is an engineer by training, bringing technical rigor to each customer engagement and partnership.

Magnetic crystal flake microstructure under a scanning electron microscope

SECURE SUPPLY CHAIN

Performance that holds under pressure

We took painstaking effort to forge trusted supply chain partnerships, develop secure metallization and manufacturing production processes, source U.S. and ally-made production equipment and software, and, where needed, custom design some of the first pieces of magnet manufacturing equipment made in the United States this century. The result is a unique capability that delivers for customers, protects sensitive data and IP, and provides traceability and transparency.

Representative forms of finished magnets
Vulcan manufactures the most powerful magnets in the world, for applications across sectors—enabled by innovations in materials science, engineering, and advanced manufacturing. Our process is rapidly adaptive and engineered to meet customer requirements for critical high-performance applications.
Magnetic powder under scanning electron microscope
Rare earth magnets are not commodities but highly bespoke manufactured components, made to-spec for each individual consumer application. Magnets are differentiated by their remanence (magnetic strength) and coercivity (heat tolerance), each spec derived by differentiated chemistry requiring unique material properties and processing specifications. Manufacturing magnets that are both high-remanence and high-coercivity is exceptionally challenging, made possible only through uniform particle size, density, distribution, and alignment. Vulcan’s team of scientists, engineers, and technicians has successfully achieved an expansive suite of magnet specs that meet requirements for defense and commercial technologies—filling a longstanding industry gap.
Magnetic press applies tens of thousands of tons of pressure in strong electromagnetic fields to create a dense magnet block
All of Vulcan’s manufacturing equipment is designed for rapid scale-up. Every piece is sourced from U.S. and allied suppliers that have demonstrated records of large-scale equipment fabrication, accelerating Vulcan’s procurement and commissioning processes.

Magnet shapes — Representative forms of finished magnets

Magnified magnet powder particles — Representative forms of finished magnets

PROCESS

Magnets made through breakthrough materials science, engineering, and manufacturing

Vulcan produces rare earth magnets from allied-sourced materials using custom-built, first-of-their-kind systems. The result is an efficient operation that minimizes environmental risks and maximizes high-performance magnetic output.

Convert raw materials

Vulcan’s process begins by converting high-purity rare earth oxides, procured exclusively from U.S. and allied suppliers, into 99.9% purity metals using a proprietary metallization process developed by our team of materials scientists and engineers. Our process revolutionizes what has traditionally been an inefficient and environmentally damaging stage of the rare earth magnet manufacturing supply chain.

Rare earth metal

Set chemistry and particle size

High-purity rare earth metals are combined in a crucible with iron, boron, and additional inputs to form unique chemistries designed to achieve specific performance requirements. During the strip casting process, this alloy is poured over a spinning wheel, instantly cooling and creating flakes of magnet crystals with the desired chemistry. This flake is transformed into very fine magnet powder through hydrogen decrepitation and jet milling–processing steps that break down the crystal structures into individual magnet particles thinner than one-tenth a strand of human hair.

Strip-casted magnetic flake

Pressing and particle alignment

Magnetic performance requires uniform particle alignment: each particle has its own magnetic field; when densely and uniformly aligned in the same direction, they compound–giving a magnet its strength. Vulcan’s custom-designed magnetic presses compact and align magnet particles into a dense block by applying tens of thousands of tonnes of hydraulic pressure under a strong electromagnetic field, aligning each particle and its magnetic field in a uniform direction.

Jet milled magnetic powder

Sinter to reinforce strength

The pressed magnetic green bodies are placed in a vacuum sintering furnace, which modulates temperature and atmospheric content over the course of several hours to produce high-density, low-porosity magnets. At this stage, the magnet achieves its final remanence (magnetic strength) and coercivity (heat tolerance).

Sintering chamber heats to up to 2,000°C

Customize to spec

Vulcan’s network of machining equipment and manufacturing sites supports both high-volume, low-mix production and low-volume, high-mix applications. Precision machining enables tight dimensional tolerances for critical applications while providing flexibility across a wide range of magnet shapes and geometries. In-house coating provides immediate protection after machining, preserving magnet quality through final delivery.

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