Ask any manufacturer who’s tried to cut magnets, and they’ll likely tell you the same thing: it’s a mess. Cutting magnetic materials—especially sintered types like NdFeB—isn’t just about slicing through a block. It’s about doing it without destroying the material in the process.
And that’s where traditional cutting methods often fail.
What Usually Goes Wrong
Here’s what we’ve seen from customers who started out using tools like band saws, abrasive wheels, or even EDM to cut magnetic blocks:
- Cracked corners and chipped edges
- Sobrecalentamiento, causing discoloration or microstructural stress
- Inconsistent tolerances, especially on small or thin parts
These issues don’t just make parts look bad. They also:
- Reduce yield
- Complicate polishing and coating
- Risk downstream failures in motors or sensors
One customer said it bluntly: “We spent more time fixing the damage than making parts.”
Cutting magnetic materials is tricky for several reasons
- They’re hard yet brittle, like ceramics
- Most generate toxic dust when abraded
- They can’t handle much mechanical shock
- Some are heat-sensitive, risking demagnetization before final processing
Traditional tools apply force, friction, and vibration. All of these are bad news for magnets.
The Wire Saw Alternative Enter the diamond wire saw.
Instead of friction and impact, diamond wire cutting relies on gentle abrasion from a high-tension, high-precision loop of diamond-coated wire. It’s more like slicing than grinding.
Here’s what changed for one client:
- Replaced ID Saw cutting with SG20
- Chipping dropped by 80%
- Post-cut polishing time cut in half
- Cutting Efiiciency increase 30%
They didn’t just improve process—they changed their entire production flow.
Cuando se trata de cutting magnetic materials, wire saws have the upper hand:
- Minimal mechanical stress: no shocks or sudden forces
- Clean surface finish: often around 5 μm Ra
- Tight tolerances: great for multi-slice jobs and small features
- Thin kerf (~0.35 mm): saves expensive material
- Wet process: no airborne dust or sparks
Plus, because the magnets aren’t yet magnetized during cutting, there’s no issue with wire movement or particle sticking.
Traditional cutting tools were never designed for rare earth magnets—and it shows. For manufacturers who want consistent results without waste, rework, or headaches, sierras de hilo diamantado aren’t an upgrade. They’re a necessity.
