Sintering, (Rare Earths, Ferrites, and Alnicos)

Pressure Bonding or Injection Molding, (Rare Earths and Ferrites)

Casting, (Alnicos)

Extruding, (Bonded Neodymium and Flexible)

Calendaring (Flexible)

The sintering process involves compacting fine powders at high pressure in an aligning magnetic field, then sintering to fuse into a solid shape. After sintering, the magnet shape is rough, and will need to be machined to achieve close tolerances. The intricacy of shapes that can be thus pressed is limited.

Rare Earth magnets may be die pressed (with pressure being applied in one direction) or isostatically pressed (with equal pressure being applied in all directions). Isostatically pressed magnets achieve higher magnetic properties than die pressed magnets. The aligning magnetic field for die pressed magnets can be either parallel or perpendicular to the pressing direction. Magnets pressed with the aligning field perpendicular to the pressing direction achieve higher magnetic properties than the parallel pressed form.

Both Rare Earth and Ferrite magnets can also be manufactured by pressure bonding or injection molding the magnet powders in a carrier matrix. The density of magnet material in this form is lower than the pure sintered form, yielding lower magnetic properties. However, bonded or injection molded magnets may be made with close tolerances "off tool" and in relatively intricate shapes.

Alnico is manufactured in a cast or sintered form. Alnicos may be cast in large or complex shapes (such as the common horseshoe), while sintered Alnico magnets are made in relatively small sizes (normally one ounce or less) and in simple shapes.

Flexible Rare Earth or Ferrite magnets are made by calendering or extruding magnet powders in a flexible carrier matrix such as vinyl. Magnet powder densities and therefore magnetic properties in this form of manufacture are even lower than the bonded or injection molded form. Flexible magnets are easily cut or punched to shape.