MAGesty — Rare-Earth-Free Iron Nitride (Fe16N2) Nanocomposite Magnet Material

Problem solved

Global dependence on China-sourced rare earths (Nd, Dy, Tb) for permanent magnets creates supply-chain risk, price volatility, and geopolitical vulnerability for EV, wind turbine, and industrial motor manufacturers. MAGesty reduces or eliminates rare-earth content while remaining compatible with existing bonded-magnet production lines.

Application contexts

• automotive-wiper-motors
• ev-auxiliary-motors
• industrial-servo-motors
• drone-motors
• household-appliance-motors
• variable-flux-motors

Technical principle

The material is a nanocomposite of (a) Fe16N2 iron nitride nanoparticles (10-200 nm), which exhibit higher saturation magnetization than pure iron without rare earths, and (b) Sm2Fe17N3 microparticles (0.3-500 µm) that provide high coercivity. The two powder fractions are blended and can be consolidated into bonded magnets via injection molding (with resin binder) or compression molding (dry press with minimal binder). The Fe16N2 phase provides the high magnetization while the Sm2Fe17N3 phase provides the coercivity and thermal stability. By varying the ratio of the two components, the composite's magnetic properties can be tuned continuously.

Typical use cases

• Automotive wiper and window-lift motors using rare-earth-free bonded magnets
• Drone propulsion motors where weight and supply-chain security are critical
• Industrial pump and fan motors requiring moderate torque density without rare-earth volatility
• Variable-flux motors for EVs where controllable magnetization reduces energy loss at high speeds