Safe, high-tolerance bonding and assembly of repulsive Halbach arrays — including non-magnetic fixture design, two-part structural epoxy and Loctite 638 retaining compound, carbon fiber wet winding for high-speed rotors, and thermal cure process control.
Best fit when the design cannot be assembled reliably by hand because adjacent magnets repel, flip, or shift before adhesive cure.
| Program Metric | Typical Range | Procurement Value |
|---|---|---|
| Bonding Shear Strength | >25 MPa (two-part structural epoxy); >20 MPa (Loctite 638 retaining compound) | Ensures magnets do not detach under extreme operational forces, vibration, or thermal cycling. |
| Carbon Fiber Sleeve Eddy Loss | Near-zero vs. stainless/Inconel sleeves (600–700 W typical eddy loss at high speed) | Carbon fiber wet winding eliminates metallic eddy current heating, enabling rotor tip speeds up to 250 m/s (0.73 Mach). |
| Rotor Balance Grade | ISO 1940 G2.5 standard; G1.0 when specified for high-speed rotors | Post-cure cylindrical grinding and dynamic balancing reduce vibration, bearing load, and noise at operating speed. |
| Fixture Repeatability | Defined by pitch, angle, or datum tolerance per fixture drawing | Fixtures control the magnet movement that normally causes assembly variation and field distortion. |
Yes. Fully magnetized assembly is reviewed with non-magnetic tooling, controlled insertion paths, and fixture-specific handling steps.
Adhesive choice depends on temperature, humidity, gap fill, shear load, chemical exposure, and whether potting or mechanical retention is also used.
Yes. Prototype fixtures are often refined into production tooling once pitch, angle, cure, and inspection criteria are approved.
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