Table of Contents
Background
CORT Magnets is a well-established leader in the development of advanced magnetic materials. Its headquarters are in Hangzhou’s high-tech industrial area. With over 15 years of experience in aerospace, defense, and precision instruments, the company has built a strong reputation. Deliver magnetic solutions that meet and often exceed strict industry standards. Cort Magnets has production facilities that cover over 12,000 square meters. These facilities include modern material analysis labs and advanced manufacturing lines. This setup allows full control over the production process, from choosing raw materials to testing the finished product.
The partnership between Cort Magnets and Aerotech Precision Components started in early 2023. The European aerospace manufacturer had important challenges in developing their next-generation inertial navigation system (INS). Aerotech’s new INS platform is designed for both commercial airliners and military aircraft. It needs magnetic parts that can stay stable in extreme temperatures, from -50°C to +200°C. These parts must also handle the strong vibrations and shocks that happen during flights. After facing many performance issues with regular neodymium-iron-boron magnets during testing, Aerotech started a thorough evaluation of suppliers. They chose Cort Magnets as their main partner for magnetic solutions.
Challenges Faced by Aerotech Precision Components
Technical Performance Requirements
Aerospace navigation systems represent one of the most demanding applications for permanent magnetic materials. Aerotech’s specific requirements included:
- Exceptional temperature stability across an operating range of -50°C to +200°C
- Minimal magnetic degradation (<3% flux loss) over an anticipated service life exceeding 10 years
- High resistance to vibration-induced demagnetization (up to 20g RMS across 5-2000Hz frequency range)
- Compatibility with existing sensor designs while providing performance enhancements
- Extensive testing of conventional neodymium-iron-boron (NdFeB)
Magnetic fields revealed significant limitations:
- 12-15% flux loss after 500 thermal cycles between -40°C and +180°C
- Magnetic performance degradation under sustained vibration testing
- Inconsistent behavior at temperature extremes, particularly below -30°C
- These performance issues threatened Aerotech’s program timeline and certification objectives, necessitating a search for alternative magnetic materials.
Customization Complexity
Aerotech’s navigation system featured multiple sensor configurations, each requiring unique magnetic components with complex geometries:
- 12 distinct magnet geometries across 3 product variants
- Tight dimensional tolerances of ±0.02mm on critical surfaces
- Complex multi-pole magnetization patterns with precise flux density requirements
- Specialized coating requirements for corrosion resistance in humid environments
The complexity of these requirements exceeded the manufacturing capabilities of Aerotech’s existing suppliers, who struggled with:
- Inconsistent achievement of specified tolerances
- Long lead times for custom tooling (typically 12-16 weeks)
- Limited ability to produce complex magnetization patterns
- High scrap rates (exceeding 15%) on complex geometries
Supply Chain Resilience
The global supply chain disruptions following the COVID-19 pandemic exposed vulnerabilities in Aerotech’s magnetic component supply chain:
- Extended lead times (up to 26 weeks) from traditional suppliers
- Inconsistent quality control across production batches
- Limited transparency into manufacturing processes
- Vulnerability to raw material price fluctuations, particularly rare earth elements
Aerotech’s procurement team identified the need for a supplier with:
- Vertically integrated production capabilities
- Geographic diversification of manufacturing facilities
- Robust inventory management systems
- Comprehensive quality control processes
Regulatory Compliance
As a Tier 1 aerospace supplier, Aerotech faces stringent regulatory requirements:
- AS9100D quality management system certification
- EN 9100 aerospace quality management certification
- REACH and RoHS compliance for all materials
- Full material traceability from raw material to finished product
- Comprehensive failure analysis capabilities and reporting
These requirements demanded a supplier with demonstrated experience in aerospace certification and documentation, as well as the ability to provide the extensive documentation packages required for regulatory approval.
Cort Magnets： Alnico Magnets Solution
Following a comprehensive technical exchange and sample evaluation process, Cort Magnets proposed a customized Alnico magnet solution addressing all of Aerotech’s critical challenges through a collaborative engineering approach.
1. Material Science Excellence
Cort Magnets team recommended Alnico 9 as the optimal material solution for Aerotech’s navigation systems, based on its exceptional material properties:
- Curie Temperature: >860°C (significantly higher than NdFeB‘s 310-400°C range)
- Temperature Coefficient: <0.02%/°C for induction (Br)
- Magnetic Stability: <0.01% flux loss per year under normal operating conditions
- Mechanical Strength: 590 MPa ultimate tensile strength (superior to most permanent magnet materials)
To validate performance claims, Cort Magnets conducted extensive testing:
Thermal Cycling Testing:
- 1,000 hours of thermal cycling between -50°C and +200°C
- <2% total flux loss measured using a Lake Shore 460 vibrating sample magnetometer
- Comparison testing showed NdFeB alternatives experiencing 3.2% flux loss under identical conditions
Vibration Testing:
- MIL-STD-810H Method 514.7 vibration profile
- 20g RMS acceleration across a 5-2000Hz frequency range
- No measurable flux degradation after 40 hours of testing
Long-term Stability Testing:
- Accelerated aging at 180°C for 5,000 hours
- The projected service life of 15+ years is based on Arrhenius modeling
- Correlation with real-time data from field trials showing <0.5% flux loss after 18 months
2. Precision Engineering & Customization
Cort Magnets deployed its advanced manufacturing capabilities to meet Aerotech’s complex customization requirements:
Advanced Powder Metallurgy Process:
- Gas atomization of Alnico alloy with particle size control (5-20μm)
- Isostatic pressing with 200MPa pressure for uniform density
- Controlled sintering cycle with precise atmosphere management
- Heat treatment with in-situ magnetic field application for anisotropic properties
Precision Machining Operations:
- 5-axis CNC grinding centers with sub-micron positioning accuracy
- Diamond wheel dressing systems for consistent finish quality
- Automated optical inspection with 100% dimensional verification
- Statistical process control (SPC) with Cpk monitoring on critical dimensions
Magnetization Technology:
- Computer-controlled multi-pole magnetization systems
- 3D magnetic field mapping for verification
- Custom fixture design for complex magnetization patterns
- In-process flux measurement and adjustment
The implementation of these advanced manufacturing technologies yielded impressive results:
- Dimensional tolerances consistently held to ±0.015mm (exceeding the required ±0.02mm)
- Lead time reduction of 40% compared to industry standards
- Scrap rates minimized to 3.2% across all geometries
- First-article inspection pass rate of 92%
3. Vertically Integrated Supply Chain
Cort Magnets’ vertically integrated production model provided Aerotech with unprecedented supply chain resilience:
Vertical Integration Elements:
- In-house raw material processing and alloy production
- Complete manufacturing from powder to finished magnet
- Advanced testing laboratories with full material analysis capabilities
- In-house tooling design and manufacturing
- Comprehensive quality control at every production stage
Supply Chain Performance Metrics:
- 99.7% on-time delivery rate over 24 months of partnership
- Inventory optimization program reducing Aerotech’s safety stock requirements by 35%
- Flexible production scheduling accommodating both high-volume and low-volume requirements
- Comprehensive traceability system from raw material lot to finished component
Risk Mitigation Strategies:
- Dual-sourcing of critical raw materials
- Strategic inventory buffering for key components
- Alternative manufacturing routes validated for critical products
- Comprehensive business continuity planning
These supply chain enhancements proved particularly valuable during the global semiconductor shortage of 2023-2024, when Cort Magnet maintained delivery schedules despite industry-wide disruptions.
4. Regulatory Compliance & Quality Assurance
Cort Magnets implemented a comprehensive quality management system specifically tailored to meet aerospace requirements:
Certifications and Compliance:
- AS9100D:2016 aerospace quality management certification
- ISO 9001:2015 quality management system certification
- REACH and RoHS compliance documentation
- NADCAP accreditation for material testing
Quality Control Processes:
- Statistical Process Control (SPC) on all critical manufacturing parameters
- 100% inspection of finished products using automated magnetic flux testing
- Destructive testing of production samples (tensile strength, hardness, composition)
- Environmental testing per relevant aerospace specifications
Documentation Package:
- Comprehensive material certification documentation
- Full traceability records from raw material to finished product
- Test data packages with all qualification testing results
- Process validation documentation and control plans
These quality assurance measures yielded significant benefits for Aerotech:
- 35% reduction in regulatory approval time for new components
- Streamlined qualification process with comprehensive data packages
- Enhanced product reliability with reduced field failures
- Improved risk management through comprehensive documentation
Project Results
The implementation of Cort Magnets’ Alnico magnets solution yielded transformative results for Aerotech’s navigation system program across multiple dimensions:
Performance Enhancement
Magnetic Performance Metrics:
- 99.98% operational reliability in extreme temperature environments
- 12% performance margin above military specification requirements
- <0.5% flux loss after 18 months of accelerated testing
- Consistent performance across all environmental conditions
System-Level Improvements:
- Navigation accuracy improved by 8% due to more stable magnetic fields
- Sensor noise reduction of 15% compared to the previous design
- Power consumption reduced by 12% through magnetic circuit optimization
- Calibration stability enhanced, extending calibration intervals by 40%
These performance improvements enabled Aerotech to exceed its technical requirements and differentiate its product in the marketplace.
Business Impact
Contract Acquisition:
- Aerotech secured a €28 million contract with a major European aerospace manufacturer
- Follow-on orders totaling €15 million for additional platform integrations
- Estimated 7-year program value exceeding €85 million
Cost Optimization:
- Total Cost of Ownership reduced by 18% through:
- 15% lower procurement costs through volume optimization
- 22% reduction in warranty claims and field service
- 30% reduction in testing and qualification expenses
- Extended service intervals reducing lifecycle costs
Market Positioning:
- Product differentiation through superior performance specifications
- 30% higher profit margins compared to competitors using conventional magnets
- Entry into new market segments requiring high-reliability components
- Enhanced brand reputation as an innovative technology provider
Customer Satisfaction Metrics
| Performance Indicator | Pre-Cort Magnets | Post-Cort Magnets | Absolute Improvement |
|---|---|---|---|
| Product Reliability Rate | 96.5% | 99.97% | +3.47% |
| Field Failure Rate | 2.8% | 0.05% | -2.75% |
| Customer Complaint Rate | 3.2% | 0.1% | -3.1% |
| On-Time Delivery | 89% | 99.7% | +10.7% |
| First Article Acceptance Rate | 76% | 98% | +22% |
| Production Scrap Rate | 12.5% | 3.2% | -9.3% |
Operational Improvements
Inventory and Supply Chain:
- 20% improvement in inventory turnover
- 35% reduction in safety stock requirements
- 40% reduction in lead times for custom components
- Elimination of production line stoppages due to magnet shortages
Engineering and Design:
- 25% reduction in design iteration cycles
- 30% faster time-to-market for new product introductions
- Enhanced design flexibility through improved magnetic component performance
- Reduced engineering support requirements for production issues
Client Testimonial
“The partnership with Cort Magnets has been transformative for our inertial navigation systems program,” said Dr. Michael Chen, Chief Engineering Officer at Aerotech Precision Components. Their Alnico magnets solution addressed our most critical technical challenges while providing unprecedented supply chain reliability.
What particularly impressed our team was the depth of technical expertise and willingness to collaborate throughout the development process. The Cort Magnets engineering team didn’t just deliver components; they became an extension of our design team, providing valuable insights that improved both performance and manufacturability.
The performance results have exceeded our expectations: our navigation systems are achieving reliability levels we previously thought unattainable, with field failure rates reduced to almost zero. This has translated directly to enhanced customer satisfaction and market differentiation.
From a business perspective, the supply chain resilience provided by Cort Magnets’ vertically integrated production has been invaluable, particularly during periods of global supply chain disruption. Their consistent on-time delivery performance and quality reliability have enabled us to meet our production commitments even in challenging circumstances.
We look forward to expanding our partnership with Cort Magnets on future programs and would highly recommend their magnetic solutions to any manufacturer facing similar technical challenges.”
Why Cort Magnes Alnico Magnets Make the Difference
In an increasingly competitive aerospace components market, Cort Magnets Alnico magnets solutions provide distinct advantages:
Material Science Leadership
Cort Magnets’ commitment to material science excellence is demonstrated through:
- Continuous R&D investment exceeding 7% of annual revenue
- In-house metallurgical expertise with specialized knowledge of Alnico alloys
- Advanced material characterization capabilities
- Proprietary heat treatment processes optimizing magnetic properties
Manufacturing Excellence
Our manufacturing capabilities represent the state-of-the-art in magnetic component production:
- Vertically integrated production from raw material to finished product
- Advanced automation with Industry 4.0 connectivity
- Statistical process control on all critical parameters
- Comprehensive testing capabilities ensure performance compliance
Customer-Centric Approach
Cort Magnets customer-focused business model includes:
- Dedicated technical account managers for major customers
- Collaborative engineering approach with customer design teams
- Flexible manufacturing to accommodate changing requirements
- Comprehensive after-sales support, including application engineering
Global Reach with Local Support
With manufacturing facilities in China and distribution centers in:
- Frankfurt, Germany (serving Europe, the Middle East, and Africa)
- Chicago, USA (serving North America)
- Singapore (serving Asia Pacific)
Cort Magnets provides truly global support with local responsiveness, ensuring timely technical assistance and supply chain resilience.
Contact us for solutions
Conclusion
Cort Magnets and Aerotech Precision Components worked well together. Their partnership shows how advanced magnetic materials can change things. This change happens when you combine great engineering skills with high-quality manufacturing. By leveraging the unique properties of Alnico 9 magnets and implementing a comprehensive solution addressing technical, manufacturing, and supply chain challenges, Cort Magnets enabled Aerotech to achieve:
- Superior product performance exceeding military specifications
- Significant business growth through major contract acquisition
- Enhanced market differentiation through technological innovation
- Improved operational efficiency and supply chain resilience
As the aerospace industry continues to demand higher performance, greater reliability, and more resilient supply chains, Cort Magnets stands ready to deliver innovative magnetic solutions that drive technological advancement and business success.
To learn how Cort Magnets’ Alnico magnets solutions can transform your product performance and market competitiveness, contact our technical sales team at info@cortmagnet.com or visit our website at https://cortmagnet.com/ to explore our comprehensive range of magnetic solutions
