This innovation reduces the “freeze-off” phenomenon that would have detrimental effects on product yield. Analysis of the new nozzle’s performance against that if its predecessor predict a narrower powder size distribution – equivalent to a 30 per cent increase in usable product. The study also showed that raising the temperature of the gas from 300°C to 500°C can reduce consumption by 25 per cent.

Ecka will continue development and plans to develop a completely new atomisation system. As a result of the collaboration, Aston University will continue to contribute to Ecka’s research and development.

The improvements in magnet performance came about through collaboration between Magnet Applications and Cranfield University. A series of designed experiments found that although lubricant, pressing speed and time maintained at temperature did not significantly affect density, die pressure, resin quality, resin temperature, coupling agent and the time in the die before pressing all has statistically significant effects.

These results showed Magnet Applications how to increase density during pressing, leading to a direct improvement in magnet performance. There was also strong evidence that corrosion protection could be increased greatly with the right choice of additives.

Corrosion in bonded NeFeB magnets is an issue in many environments, particularly in automotive applications, and major improvements in resistance can represent distinct commercial advantage.