Magsafe Magnet Project Overview
Casetey LLC is a big wireless charging wholesaler in the US. The goal was to create a new magnetic charging system using the MagSafe magnet. This system required perfect alignment, a secure hold, and improved charging efficiency for iPhones. However, due to technical and cost issues, the current MagSafe magnet cannot meet these needs.
So Casetey LLC teamed up with CORT MAGNETS, a one-stop magnet customization solution provider. Together, they wanted to create custom MagSafe magnets that would redefine the MagSafe experience.
Magsafe Magnet Key Challenges
1. Precise Magnetic Alignment
- The MagSafe magnet ring (inner diameter: 4.5±0.002mm, outer diameter: 7.8±0.002mm) had to align with iPhone MagSafe coils within ±1μm.
- Standard magnets exhibited alignment errors of up to 5 μm, significantly impacting charging efficiency.
2. Optimal Magnetic Force
- For the magnetic MagSafe case and charging accessories to stay attached, the magnet needed a 12- 18N pull force.
- Conventional magnets were either too weak (< 10N) or too strong (> 25N, damaging the device).
3. Durability in Various Environments
The MagSafe magnet had to withstand:
- Temperature range-20°C to 60°C (simulating real usage)
- 3% NaCl humidity exposure (ASTM D4585) without performance loss due to corrosion
- 10,000+ attach-detach cycles without magnetic degradation.
4. Mass Production Consistency
Casetey LLC required 2 million MagSafe magnet units per year with ±2% consistency in magnetic properties. Mass-producing custom, small form factor magnets was a big challenge.
CORT MAGNETS’s Engineered Solution
1. Magsafe magnet Material & Coating Innovation
N52 Grade Optimization for MagSafe
- We used custom N52 magnets such as N52-D54.0-46.0-0.7-36 (fan type)-1 (runway type) N52 Ni and W4.4-4-0.7 (fan type)-N52-Ni. These had a 50 MGOe energy product. We calibrated them to meet Apple’s MagSafe compatibility standards for seamless integration with iPhones.
- For the tail magnet, we used the one with material code F18-5.9-0.7–N35B-ZN (Level 3 Magnetization), which had the right magnetic properties for specific accessory parts.
Triple-Layer Corrosion Protection
- First, a Ni-P (20μm) layer provided basic corrosion protection. Then, a 3μm ceramic intermediate layer enhanced durability. Finally, a 2μm PTFE topcoat enabled smooth attachment. These magnets passed a 2,000-hour humidity test (ASTM D4585) with no performance issues.
2. Magsafe magnet Advanced Design & Simulation
Magnetic Field Simulation with COMSOL
We optimized the Magsafe magnet ring’s magnetic field pattern to match iPhone MagSafe coil receptors. Compared to generic magnets, we reduced magnetic interference by 22%. Our simulation accounted for real-life scenarios like device tilting.
Laser – Guided Micro – Machining
We used the Trumpf TruMicro 7050 for laser-assisted micro-machining of the MagSafe magnet ring. We achieved a precision of ±0.5μm on the outer and inner diameters. This created a Ra 0.3μm surface finish. This finish is great for sensor and magnet alignment. It also cut material waste by 25% compared to traditional methods.
Automated Magnetization Fixture
Our custom 2-axis magnetization fixture provided even magnetic pole orientation with ±0.5° precision. This reduced the post-assembly calibration time for MagSafe accessories by 40%.
3. Magsafe magnet’s Collaborative Development Cycle
- We used 3D printing to create stainless steel molds with the EOS M 290. We had the first Magsafe magnet prototypes ready in 48 hours. With digital twin simulations, we did 20 design iterations in a week, 50% faster than traditional prototyping.
- Vertical integration (from raw material to coating) was 6 weeks (vs industry average of 10 weeks).
Project Outcomes
Performance Benchmarks
- Charging Efficiency: With the MagSafe magnet aligned precisely, MagSafe-compatible devices charged faster.
- Durability: These magnets went through 12,000 attach and detach cycles. They also passed a 1,500-hour humidity test. They meet the MagSafe standards for industry.
Operational Excellence
- Assembly Cost Savings: With ±1μm precision, we reduced manual adjustments in MagSafe accessory assembly by 60%. A lot of cost saved
- Quality Consistency: 99.5% first-pass yield, met industrial’s supply chain requirements.
Market Leadership
- The MagSafe-compatible products are equipped with our custom MagSafe magnets. Casetey LLC received a $3 million contract with a big mobile accessory retailer. This helped them increase their market share in the MagSafe ecosystem by 12%.
Client Testimonial
“CORT MAGNETS made our MagSafe accessory dream come true. Their expertise in MagSafe magnet design, precision manufacturing, and meeting industrial standards was key. We not only upgraded our product line but also became a MagSafe innovation leader.”
— Head of Product Development, Casetey LLC
“Beyond the technical achievements, their smart factory and rapid prototyping helped us meet a tight launch schedule. We’re extending our partnership for future MagSafe-centric product generations.”
— Senior Supply Chain Manager, Casetey LLC
Conclusion: Redefining Mobile Magnetic Charging
Custom Magsafe magnet solutions solve the problems of precision, durability, and user experience in mobile charging. CORT MAGNETS sets a new standard for MagSafe accessories. We do this by using optimized N52 materials, like our coded magnets. We also use laser precision manufacturing and digital engineering. As the mobile industry advances in wireless charging, these solutions will be key to the next MagSafe innovations.
