Flat Magnet Linear Motion
Contact Us Now
FAIZEAL designs and manufactures flat magnet linear motion systems — high-performance NdFeB magnet track assemblies and matched ironless / iron-core linear motor forcer coils that convert a rotary motor’s principle of operation into linear thrust. Our planar linear motor magnet arrays deliver thrust forces from a few newtons to several thousand newtons at continuous velocities from 0 m/s up to 15 m/s, with the smoothest velocity regulation and the lowest cogging available in the industry today.
A flat magnet linear motor is best understood as a rotary servo motor that has been unrolled flat and laid out as a straight line. The rotor (coils, encapsulated in epoxy) is replaced by a moving forcer, and the stator (magnets on steel) is replaced by a stationary magnet track — a precision array of N42, N45, N48, or N52 sintered NdFeB magnets bonded to a steel back-iron. The permanent magnet linear motor principle eliminates all mechanical transmission elements between the motor and the payload, delivering direct-drive linear thrust with sub-millisecond response, zero backlash, and a maintenance-free operating life exceeding 100,000 hours.
Whether you are building a high-speed pick-and-place linear motor for semiconductor wafer handling, a CNC linear motor for precision machining, a laser-cutting linear motor for sheet metal processing, an inspection linear motor for flat-panel display metrology, or a custom linear actuator for an OEM automation platform, FAIZEAL’s flat magnet linear motion systems give you the direct-drive performance your application demands.
The flat magnet linear motor is constructed from three primary sub-assemblies: the magnet track (a steel channel filled with alternating N-pole and S-pole NdFeB magnets, fully encapsulated), the forcer (a coil assembly encapsulated in epoxy, sometimes with a thermal management jacket), and the bearing system (typically an air bearing or linear rail bearing that maintains the forcer-to-track air gap with sub-micrometer precision).
The principle of operation is identical to a rotary brushless permanent magnet motor. The forcer’s three-phase windings are commutated in sequence to create a traveling magnetic field, which interacts with the NdFeB magnet track to produce thrust. The forcer moves along the track with the same force-vs-speed characteristics as a rotary motor would exhibit under load, and the force is directly proportional to the current, with no mechanical conversion losses in between.
The flat magnet linear motor differs from a tubular linear motor, voice-coil actuator, or linear induction motor in that the active magnetic circuit is open on one side (the air gap) and the forcer slides over a flat magnet track. This geometry is ideal for long-stroke applications, because the magnet track can be extended in 100 mm, 200 mm, or 500 mm modular increments to any length required, while the forcer remains a short, compact unit that translates along the entire track length.
Direct-Drive Linear Thrust — The forcer is directly coupled to the payload, with no leadscrew, ball screw, timing belt, rack-and-pinion, or worm gear between motor and motion. This eliminates all mechanical transmission losses, all backlash, and all mechanical wear. The result is a direct drive linear motor with a theoretical mechanical efficiency of 100% and a measured efficiency above 95% in production units.
Wide Force-Speed Range — From stalled or low-speed high-force operation (holding force up to several kN depending on forcer size) to high-velocity operation up to 15 m/s, the flat magnet linear motor delivers continuous force over a wider speed range than any mechanical transmission-based system. The iron-core forcer provides maximum thrust at the cost of higher cogging force; the ironless forcer provides near-zero cogging and ultra-smooth motion at the cost of slightly lower continuous force.
Ironless Forcer Option for Ultra-Precision Applications — The ironless forcer contains no iron laminations, so there is no magnetic attraction force between the forcer and the NdFeB magnet track. This eliminates the iron-induced cogging force, makes the forcer significantly lighter (typically 50% to 70% lighter than an equivalent iron-core forcer), and is the preferred choice for air-bearing applications where the speed stability must be below 0.1% or where extremely high accelerations above 10 g are required.
Iron-Core Forcer Option for Maximum Thrust — The iron-core forcer uses laminated silicon steel poles to concentrate flux and provide maximum continuous thrust. Iron-core forcers deliver 2× to 4× the continuous force of an equivalent ironless forcer at the cost of higher cogging and a small constant attraction force between forcer and track.
Halbach Array Magnet Track (Optional) — For ultra-premium performance, FAIZEAL offers Halbach array magnet tracks that increase air gap flux density by 30% to 60% compared with conventional radial magnetization, while reducing the track’s external stray field. Halbach tracks are recommended for ultra-precision positioning, semiconductor lithography, and flat-panel display inspection applications.
Modular Track Length — Magnet tracks are manufactured in modular 100 mm, 200 mm, 300 mm, and 500 mm segments and joined end-to-end to create tracks of any length from 100 mm to over 10 meters. There is no upper length limit. Standard module lengths are 96 mm, 144 mm, 192 mm, 240 mm, and 288 mm, with custom pole pitches available.
Sub-Millisecond Response — The moving forcer has a very low mass (typically 0.5 to 5 kg depending on size), and the absence of mechanical transmission means the flat magnet linear motor can accelerate from 0 to full speed in sub-millisecond timescales. Acceleration capability ranges from 1 g for heavy-payload iron-core forcers to over 50 g for small ironless forcers.
Zero Backlash and Zero Mechanical Wear — There is no mechanical contact between the forcer and the track in the magnetic circuit. The only contact points are the bearing system (linear rails, air bearings, or magnetic bearings). The permanent magnet linear motor has zero mechanical wear, zero backlash, and zero maintenance requirements for the magnetic assembly itself.
Long Lifetime, Low Cost of Ownership — The only wear parts in a flat magnet linear motion system are the bearings. With air bearings, the system lifetime is essentially unlimited (>100,000 hours MTBF). With linear rail bearings, service life is 50,000 to 100,000 km depending on load and lubrication. Either way, the direct drive linear motor eliminates the consumable parts (drive belts, leadscrews, gear oils) that drive up the lifetime cost of mechanical transmission systems.
The choice between ironless and iron-core forcer depends on your application priorities.
For ultra-precision applications, choose the ironless forcer. The lack of iron means zero magnetic attraction to the track, zero cogging force, and zero reluctance-induced harmonics. Pair with air bearings for sub-nanometer position stability and speed regulation below 0.1%. This configuration is the standard for semiconductor lithography, flat-panel display inspection, laser interferometer stages, and ultra-precision metrology. The trade-off is that ironless forcers deliver lower continuous force (typically 10 to 200 N depending on size) and require larger magnet tracks for equivalent thrust.
For maximum thrust and continuous-duty applications, choose the iron-core forcer. Iron-core forcers use laminated silicon steel pole pieces to concentrate flux and produce 2× to 4× higher continuous thrust than ironless units. The trade-off is a small constant attraction force (typically 200 to 1000 N depending on size) between forcer and track, plus a periodic cogging force (typically 1% to 3% of rated thrust) that the motion controller must compensate. Iron-core forcers are the standard for CNC machining, laser cutting, heavy material handling, and high-thrust pick-and-place.
For the optimum balance, choose the ironless forcer with Halbach magnet track. The Halbach array increases the air gap flux density of an ironless forcer by 30% to 60%, recovering most of the thrust penalty while keeping the zero-attraction and zero-cogging benefits of the ironless design.
FAIZEAL flat magnet linear motion systems are offered with the following standard and customizable specifications.
Magnet track material is N42, N45, N48, or N52 sintered NdFeB bonded to a low-carbon steel back-iron. Halbach array track available on request. Track pole count is selectable from 2-pole (long pitch, low force) to 64-pole (short pitch, high force) per track segment. Standard pole pitches are 12 mm, 15 mm, 18 mm, 24 mm, 30 mm, 36 mm, 45 mm, and 60 mm, with custom pole pitches from 5 mm to 120 mm available on request. Track segment lengths are 96 mm, 144 mm, 192 mm, 240 mm, 288 mm, and 384 mm as standard, with custom lengths up to 1000 mm per segment. Total track length is 100 mm to over 10 meters by joining segments.
Magnet surface treatment is Ni-Cu-Ni triple-layer electroplating for standard environments, or epoxy coating for harsh chemical or marine environments. Track encapsulation is optional stainless steel cover, aluminum cover, or Kapton tape. Track straightness tolerance is 0.02 mm per 1000 mm segment, with overall track straightness of 0.05 mm per meter for assembled tracks.
Forcer coil construction is three-phase Y or delta wound, with Class H (180°C) or Class N (200°C) insulation. Forcer encapsulation is epoxy vacuum impregnation as standard, with thermal potting or aluminum housing available. Forcer thermal management is natural convection, forced air, or water cooling, depending on continuous power dissipation. Forcer mass is 0.5 to 50 kg depending on thrust rating. Forcer protection class is IP54 standard, IP65 optional, IP68 on request.
Performance parameters: continuous thrust from 5 N to 5000 N. Peak thrust from 15 N to 15000 N. Maximum velocity up to 15 m/s (iron-core, depends on bus voltage) or 25 m/s (ironless, no eddy current limit). Maximum acceleration from 1 g (iron-core, heavy load) to 50 g (ironless, light load). Position resolution limited by encoder, typically 0.1 μm to 1 μm. Repeatability ±0.5 μm with air bearing and linear encoder.
Operating environment: ambient temperature 0 to 40°C standard, -20 to 80°C on request. Relative humidity 10% to 90% non-condensing. Altitude up to 2000 m standard.
FAIZEAL flat magnet linear motion systems serve a wide range of high-precision industrial applications.
Semiconductor Wafer Handling and Lithography — The ironless forcer with Halbach magnet track delivers the zero-cogging, sub-nanometer stability required for 300 mm and 450 mm wafer handling, EUV lithography stages, and inspection metrology. Compatible with class 1 cleanroom environments.
Flat Panel Display Inspection and Manufacturing — The long-stroke capability of the planar linear motor (tracks from 1 meter to over 5 meters) is ideal for LCD, OLED, and micro-LED panel inspection, repair, and laser annealing. Speed stability below 0.1% is achievable with air bearing + ironless forcer + Halbach track.
Pick-and-Place and High-Speed Assembly — The sub-millisecond response and 10 g to 50 g acceleration of the ironless forcer drive the highest-throughput pick-and-place machines in the electronics, pharmaceutical, and food packaging industries. Typical cycle times are 30 to 50 picks per minute for surface mount device placement and 100 to 200 picks per minute for component insertion.
CNC Machining and Laser Cutting — The iron-core forcer delivers the high continuous thrust (up to 5000 N) required for laser cutting heads, water jet heads, and CNC tool carriers. The absence of mechanical wear in the direct drive system eliminates backlash and improves machining accuracy over time.
Precision Scanning and Inspection — Long-stroke linear motor stages with ironless forcer drive laser scanners, X-ray detectors, and vision system cameras in metrology, non-destructive testing, and reverse engineering applications. Position accuracy of ±1 μm is achievable with linear encoder feedback.
Solar Panel and Battery Manufacturing — The wide speed range and high acceleration of the flat magnet linear motor drive wafer handling, cell printing, and module assembly equipment in solar panel and lithium-ion battery production lines. Compatible with cleanroom and dry-room environments.
Medical and Pharmaceutical Automation — The ironless forcer’s zero-attraction force and ultra-clean encapsulation make it suitable for medical device assembly, pharmaceutical filling lines, and diagnostic equipment. Biocompatible encapsulation and cleanroom-compatible materials are available.
Industrial Automation and Robotics — The direct drive linear motor replaces pneumatics, leadscrews, and timing belts in general industrial automation, delivering higher throughput, lower maintenance, and longer life. Standard linear motor modules integrate easily with PLC, motion controller, and robot systems.
FAIZEAL specializes in custom flat magnet linear motion solutions for OEM and ODM customers worldwide. Our engineering team works directly from your application requirement, motion profile, or existing mechanical drawing to deliver an optimized NdFeB magnet track and forcer assembly in as few as 5 to 10 business days for prototype.
Track Length Customization — Standard track segments from 96 mm to 384 mm, joined end-to-end to any length from 100 mm to over 10 meters. No upper length limit. Custom segment lengths from 50 mm to 1000 mm available on request.
Pole Pitch and Pole Count Customization — Standard pole pitches 12 mm, 15 mm, 18 mm, 24 mm, 30 mm, 36 mm, 45 mm, 60 mm. Custom pole pitches from 5 mm to 120 mm. Pole counts from 2 to 64 per segment, with infinite extension by joining segments.
Magnet Grade Selection — N42, N45, N48, N50, N52, N54 standard grades. High-temperature variants N42SH, N40UH, N38EH, N33AH for operating environments above 80°C.
Forcer Thrust Customization — Continuous thrust from 5 N to 5000 N. Peak thrust from 15 N to 15000 N. Custom forcer winding configurations for specific voltage, current, and bus voltage requirements (24 VDC, 48 VDC, 72 VDC, 96 VDC, 240 VAC, 400 VAC, 480 VAC).
Halbach Array Upgrade — Conventional radial magnetization tracks can be upgraded to Halbach array configuration for 30% to 60% higher air gap flux density. Recommended for ultra-precision applications and high-acceleration pick-and-place.
Mounting and Integration Customization — Standard track mounting via M4, M5, M6, M8 threaded holes on 50 mm, 100 mm, 150 mm pitch. Custom mounting holes, T-slots, dovetails, and weld-on tabs per drawing. Forcer mounting via top, bottom, or side mounting flanges, with custom adapter plates for direct integration to your payload or stage.
Cable and Connector Customization — Standard cable length 1 m, 3 m, 5 m, 10 m. Custom cable lengths from 0.5 m to 50 m. Standard connector types Molex, JST, Harting, M12, M23. Custom connector pinouts and special-purpose connectors (vacuum feedthrough, right-angle, locking) on request.
Application Engineering — Every custom flat magnet linear motion project includes DFM review, magnetic circuit FEA simulation (Ansys Maxwell or JMAG), force-speed-thermal calculation, lifetime estimation, and prototype testing. FAIZEAL’s engineering team provides complete linear motor design and manufacturing support from concept through mass production.
10 Years of Magnetic Assembly Expertise — Since 2017, FAIZEAL has been engineering custom magnetic components for customers worldwide. Our deep experience in NdFeB magnet tracks, Halbach array rotors, ironless forcer winding, and planar linear motor design makes us the ideal partner for your high-precision linear motion project.
In-House R&D and Manufacturing — From magnet grade selection to FEA simulation to magnet array assembly to forcer winding to final testing, every step is controlled in-house at our Ningbo facility. This vertical integration ensures consistent quality, fast iteration on custom designs, and complete traceability from raw material to finished product.
Custom-First Philosophy — Unlike catalog-only linear motor suppliers, FAIZEAL treats every inquiry as a custom engineering project. We listen to your application, design the optimal flat magnet linear motion solution, manufacture it to specification, and support you through integration. No project is too small, no size too large, no specification too demanding.
Prototype to Mass Production — Prototype lead time 5 to 10 business days. Mass production MOQ 50 pieces with 20 to 25 business day lead time. For established programs, we maintain safety stock and kanban delivery to support JIT production.
Global Shipping and Support — FAIZEAL exports to North America, Europe, Southeast Asia, the Middle East, and Oceania. Full English and Chinese technical documentation, engineering support, and on-site installation assistance are available. Trade terms include EXW, FOB, CIF, and DDP.
Quality Systems — Every magnet track is dimensionally inspected using CMM, magnetically tested using Helmholtz coil flux mapping, and dynamically tested for force-speed performance before shipment. Forcer coils undergo hipot testing, surge testing, and insulation resistance testing. Material certificates, dimensional reports, and magnetic performance reports accompany every batch.
Primary keywords: flat magnet linear motor, planar linear motor, NdFeB magnet track, linear motor magnet track, permanent magnet linear motor, direct drive linear motor, ironless linear motor, iron core linear motor, linear servo motor, linear motor manufacturer, linear motor supplier, linear motor OEM, linear motor ODM, flat magnet linear motion, Halbach array linear motor.
Secondary keywords: linear motor China supplier, custom linear motor, linear motor magnetic assembly, brushless linear motor, linear motion system, linear actuator, linear positioning system, linear motor forcer, linear motor stator, NdFeB linear motor magnet, sintered NdFeB linear motor, high speed linear motor, high acceleration linear motor, low cogging linear motor, zero cogging linear motor.
Application keywords: semiconductor linear motor, wafer handling linear motor, flat panel display linear motor, FPD linear motor, OLED linear motor, pick and place linear motor, CNC linear motor, laser cutting linear motor, inspection linear motor, PCB assembly linear motor, solar panel linear motor, battery manufacturing linear motor, medical linear motor, pharmaceutical linear motor, food packaging linear motor, lithography linear motor, metrology linear motor, laser scanner linear motor.
Long-tail keywords: custom flat magnet linear motor, custom NdFeB magnet track, ironless forcer winding, iron core forcer winding, Halbach magnet track, Halbach array linear motor track, modular linear motor track, long stroke linear motor, planar linear motor manufacturer China, direct drive linear motion system, high precision linear motor stage, sub-micron linear motor, cleanroom linear motor, air bearing linear motor, linear motor for semiconductor equipment, linear motor for flat panel display, linear motor for solar manufacturing, linear motor for lithium battery production.
Material and grade keywords: N42 NdFeB linear motor, N45 NdFeB linear motor, N48 NdFeB linear motor, N52 NdFeB linear motor, N54 NdFeB linear motor, N42SH linear motor, N40UH linear motor, rare earth linear motor, sintered NdFeB linear motor track.
Q1: What is a flat magnet linear motor? A flat magnet linear motor is a direct-drive linear actuator that converts electrical energy into linear motion using the same principle as a rotary brushless permanent magnet motor, but with the rotor and stator “unrolled” into a flat configuration. The stationary part is a magnet track made of NdFeB magnets bonded to a steel back-iron. The moving part (forcer) is a coil assembly encapsulated in epoxy. When three-phase current is applied to the forcer windings, a traveling magnetic field is generated that interacts with the magnet track to produce thrust. The result is direct linear motion with no mechanical transmission in between.
Q2: How does a flat magnet linear motor differ from a leadscrew or ball screw actuator? A leadscrew or ball screw actuator converts rotary motion to linear motion through a mechanical screw, which introduces backlash, friction, wear, and limited speed. A flat magnet linear motor produces linear thrust directly with no mechanical transmission, eliminating backlash, friction-induced wear, and speed limitations. The direct drive system is faster, more accurate, more reliable, and requires less maintenance.
Q3: What is the difference between ironless and iron-core linear motors? The ironless linear motor has a coil assembly with no iron laminations in the magnetic circuit, so there is no magnetic attraction force between the forcer and the magnet track. This eliminates cogging, reduces forcer mass, and makes the ironless design ideal for air bearing and ultra-precision applications. The iron-core linear motor has laminated silicon steel pole pieces that concentrate flux and produce higher continuous thrust, but introduce a small constant attraction force and periodic cogging force. Iron-core designs are preferred for high-thrust CNC and laser cutting applications.
Q4: What is the maximum speed of a flat magnet linear motor? The maximum speed depends on the forcer design and the bus voltage. Iron-core forcers typically achieve up to 15 m/s, limited by eddy current losses in the iron laminations. Ironless forcers can achieve up to 25 m/s because there is no iron to generate eddy current losses. The maximum practical speed is often limited by the bearing system, encoder bandwidth, and controller sample rate, not by the magnetic circuit.
Q5: Can the magnet track be custom-length? Yes. FAIZEAL manufactures magnet tracks in modular 96 mm, 144 mm, 192 mm, 240 mm, 288 mm, and 384 mm segments, and joins them end-to-end to create tracks of any length from 100 mm to over 10 meters. There is no upper length limit. Custom segment lengths from 50 mm to 1000 mm are also available.
Q6: What is a Halbach array linear motor track? A Halbach array linear motor track is a magnet track in which the magnetization direction of each magnet segment is rotated progressively, concentrating the magnetic field on one side (the air gap) and suppressing it on the other (the back-iron side). Compared with conventional radial magnetization, a Halbach track increases air gap flux density by 30% to 60% and reduces the external stray field to near zero. Halbach tracks are recommended for ultra-precision positioning, semiconductor lithography, and high-acceleration pick-and-place.
Q7: What is the speed stability of an ironless linear motor with air bearings? With an ironless forcer, a Halbach magnet track, and an air bearing system, speed stability of better than 0.1% is achievable over the full velocity range. Position stability is sub-nanometer with closed-loop control and a high-resolution linear encoder. This is the configuration used in semiconductor lithography and metrology stages.
Q8: Can FAIZEAL provide matching forcer winding and track? Yes. FAIZEAL can supply the magnet track only, the forcer coil only, or a fully matched track-and-forcer pair optimized for your specific application. The matched pair approach guarantees optimal performance because the magnetic circuit simulation accounts for both sides of the air gap simultaneously.
Q9: What is the lead time for a custom flat magnet linear motion system? Prototype lead time is 5 to 10 business days from drawing approval. Mass production lead time is 20 to 25 business days. For established programs, safety stock and kanban delivery can reduce delivery to 1 to 2 weeks. Expedited prototype service is available for urgent requirements.
Q10: Does FAIZEAL support OEM and ODM? Yes. FAIZEAL supports full OEM and ODM programs including custom branding, custom packaging, custom documentation, custom labeling, and custom part numbers. We routinely ship under customer brand names for distribution partners and system integrators.
Send your motion profile, payload specification, or existing mechanical drawing to FAIZEAL and receive a complete engineering package within 5 business days, including DFM review, magnetic circuit FEA simulation, force-speed-thermal calculation, custom prototype quotation, and mass production timeline.
Whether you need a single custom prototype for evaluation or 10,000 pieces per year for series production, FAIZEAL has the engineering depth, manufacturing capacity, and quality systems to deliver.
No project too large. No specification too demanding. No motion problem too hard.
Contact FAIZEAL today for custom flat magnet linear motion systems, NdFeB magnet tracks, ironless and iron-core forcer coils, Halbach array linear motor tracks, and specialty linear motor magnetic assemblies. Engineering support available in English and Chinese. Global shipping.
FAIZEAL — Custom Magnetic Assemblies, Engineered to Your Specification.
