Magnetic Bead Insert Moulding
This project combined insert moulding with multi-colour production to create magnetic beads embedding neodymium magnets within colourful plastic shells. Each 10mm bead contains a precisely positioned N52 magnet, overmoulded with PP in 8 vibrant colours for educational construction toys and creative design applications.
Manufacturing Process
Neodymium magnets are loaded into a 64-cavity mould by a vibratory bowl feeder and pick-and-place robot. Magnetic pins in the cavity hold each magnet centred during injection. The PP overmould encapsulates the magnet completely, providing electrical insulation and corrosion protection.
Colour changes are managed through a quick-change material hopper system, allowing 8 colours per shift with minimal purging waste. Cycle time: 6 seconds for 64 beads simultaneously.
Material & Safety
The PP shell is EN 71 certified (toy safety directive), phthalate-free, and passes the small parts test (CPSC 16 CFR 1501). The magnet encapsulation is tested per EN 71-1 Annex J for magnetic flux index to ensure compliance with swallowing hazard regulations.
Quality Assurance
100% magnetic polarity testing via automated sensor station. Weight checking detects missing magnets. Pull-out testing (>50N) verifies encapsulation integrity. ISO 9001:2015 certified production.
Applications
STEM educational toys, creative construction systems, therapeutic fidget tools, architectural models, magnetic jewellery components, and interactive art installations.
Frequently Asked Questions
How strong are the embedded magnets?
Each bead contains a 6x2mm N52 neodymium magnet providing approximately 0.8kg pull force. Stronger or weaker magnets available on request.
What safety certifications do the beads carry?
EN 71 (EU toy safety), ASTM F963 (US), ISO 8124, and CPSC compliance. All materials are REACH and RoHS compliant.
Technical Specifications
Material: PP (EN 71 certified) | Magnet: N52 neodymium 6x2mm | Bead size: 10mm sphere | Mould: 64-cavity | Cycle: 6s | Colours: 8 standard | Certifications: EN 71, ASTM F963