| HS Code | 439836 |
| Material | PA12 with ferromagnetic iron filler |
| Density | 3.1 g/cm³ |
| Melting Temperature | 178 °C |
| Tensile Strength | 45 MPa |
| Elongation At Break | 2.0 % |
| Tensile Modulus | 10000 MPa |
| Flexural Strength | 80 MPa |
| Flexural Modulus | 9000 MPa |
| Charpy Impact Strength 23 C | 15 kJ/m² |
| Thermal Conductivity | 1.6 W/(m·K) |
| Volume Resistivity | 1e12 Ω·cm |
| Saturation Magnetization | 1.2 T |
| Coercivity | 2.0 kA/m |
As an accredited Barlog Plastics KEBABLEND MW FE 200102 PA12 for Magnetic Components factory, we enforce strict quality protocols—every batch undergoes rigorous testing to ensure consistent efficacy and safety standards.
| Packing | Supplied in sealed 25 kg bags, labeled with product identification and safety data, protected from moisture for magnetic component processing. |
| Container Loading (20′ FCL) | 20′ FCL: one full container of Barlog Plastics KEBABLEND MW FE 200102 PA12, a specialty compound for magnetic components, loaded securely. |
| Shipping | Barlog Plastics KEBABLEND MW FE 200102 is a polyamide-12 (PA12) compound with ferromagnetic fillers for magnetic components. Ship as non-hazardous plastic granules in sealed, moisture-proof bags or drums. Protect from moisture and static; use dry, ventilated transport. No special hazard class, but avoid ignition sources and high temperatures. |
| Storage | Store KEBABLEND MW FE 200102 in its original, unopened packaging in a cool, dry place away from direct sunlight, heat sources, and moisture. Keep the container sealed when not in use to prevent PA12 from absorbing humidity. Ideal storage temperature is below 30°C. Use within the manufacturer’s stated shelf life to ensure consistent magnetic and processing performance. |
| Shelf Life | Shelf life is typically 2 years when stored unopened in original packaging under dry, cool conditions, avoiding moisture and heat. |
Anti-lock braking system wheel speed sensor rings manufactured from ferrite-loaded polyamide 12 are a direct alternative to thermoset-bonded ferrite rings where radial pole count and air-gap stability must be maintained across a wide temperature range. In this segment, Barlog Plastics KEBABLEND MW FE 200102 PA12 is processed as a single-shot injection-moulded ring that is subsequently press-fitted to the bearing or hub assembly after magnetisation. The PA12 matrix exhibits lower equilibrium moisture absorption than PA6 or PA66, which reduces pole-to-pole dimensional drift in humid wheel-end environments. Dimensional inspection is performed after conditioning under ISO 291:2008 at 23 °C and 50 % RH. The compound is used at 100 wt% as supplied, without let-down into unfilled PA12. Regrind from sprues and runners may be reintroduced at a maximum of 15 wt% of the shot mass only when the resulting batch passes full magnetic certification, including component-fixture residual induction measurement. Additions above this threshold increase melt viscosity fluctuation and produce local remanence gradients across the ring; published data for alternative dilution ratios in this specific grade is limited, and reduction of filler content below the supplier-specified level is not recommended for safety-relevant wheel speed sensing. Material data must be entered into IMDS, and compliance with the RoHS Directive 2011/65/EU Annex II amendment (EU) 2024/1410 must be documented. REACH Regulation (EC) No 1907/2006 Article 33 SVHC reporting triggers a lot-level review of the compound formulation. Magnetic hysteresis for the specimen is tested according to IEC 60404-5:2015 using a closed-circuit permeameter. Tensile strength and elongation at break are generated under ISO 527-2:2012 at a test speed of 5 mm/min. Pre-drying is executed in a dehumidified-air dryer at 80 °C for 4–6 h until residual moisture falls below 0.10 %; higher water content results in splay and inconsistent magnetic filler distribution during plastication. The injection unit uses a wear-protected screw, bimetallic barrel and hardened check ring because the ferrite fraction is abrasive. Mould temperature is held in a closed-loop water system, and gate placement is offset from the outer pole track to prevent weld lines crossing magnetic boundaries. After demoulding, the ring is magnetised in a multi-pole fixture driven by a capacitor-discharge magnetiser reaching the saturation field specified by the compound manufacturer. Post-magnetisation pole pitch is verified with a Hall probe array, and surface temperature, holding pressure and peak magnetiser output are recorded for each cavity. Terminal products are multi-pole thermoplastic encoder rings installed in active wheel speed sensors on passenger car and light commercial vehicle axle assemblies.
In thin-wall HVAC damper actuators, the limiting variable is not processing temperature but the combined viscosity of ferrite filler and PA12 matrix during filling. KEBABLEND MW FE 200102 PA12 is applied in rotor position magnet rings with wall sections below 1.2 mm to fit compact gear housings. At a flow-path-to-wall-thickness ratio above 150:1, short shots and non-uniform filler orientation occur in tools without sequential valve gate control. In such designs, the compound is injected at 100 wt% as supplied. Dilution with unreinforced PA12 to improve filling by 10 wt% decreases residual induction by a measurable margin and is acceptable only if the sensor air-gap threshold is re-certified with the diluted lot. Dilution above 15 wt% is contraindicated because the magnetising fixture can no longer saturate the polymer-dispersed ferrite fraction, producing partially magnetised poles and signal asymmetry. For HVAC components installed in European and North American systems, electrical safety testing follows IEC 60335-1:2020 and IEC 60335-2-40:2018. Material tracking uses ISO 11469:2016 marking. Restricted substance compliance is checked against RoHS Directive 2011/65/EU Annex II and REACH Regulation (EC) No 1907/2006 Article 33. Tensile modulus, yield stress and strain are determined according to ISO 527-2:2012; notched Charpy impact values are obtained under ISO 179-1:2020. Tooling for thin-wall rings uses polished wear-resistant cavities and vacuum venting to reduce gas trapping. The injection velocity profile is established by short-shot study and adjusted until cavity-pressure sensors record a stable pressure trace in the thin section. Packing pressure is held at a level that compensates for PA12 crystallisation shrinkage without overpacking the ferrite-rich melt. Cylinder temperature is maintained inside the supplier TDS window, and the nozzle tip orifice is enlarged compared with unfilled PA12 to reduce shear heating. Mould temperature is controlled at 80 °C to promote consistent crystallinity and dimensional stability. At relative humidity above 60 % in the production hall, pre-dried material must be consumed within 30 min or fed from a dry-air hopper to prevent moisture regain. Post-mould magnetisation uses a ring fixture with a two-pole or four-pole pattern, and the fixture is aligned to the gate vestige to avoid parasitic pole distortion. Terminal products are magnet rings for rotary position feedback in damper actuators for commercial HVAC systems.
Rotor-mounted radial magnet rings for brushless DC motor position feedback are injection-moulded without an alignment field, then magnetised after solidification using a multi-pole fixture. KEBABLEND MW FE 200102 PA12 is processed at 100 wt% as supplied; regrind derived from rejected rings is limited to 10 wt% of the shot mass and only for components not used in safety-critical servo axes. External lubricants or plasticisers are not permitted because these additives migrate to the surface and interfere with automated optical pole verification. Motor feedback assemblies used in industrial automation typically reference IEC 60034-1:2022 for rotating electrical machines and IEC 61800-5-1:2007 for adjustable-speed electrical power drive systems. Material declarations satisfy REACH Regulation (EC) No 1907/2006 Article 33 and RoHS Directive 2011/65/EU Annex II. Mechanical properties are characterised by ISO 527-2:2012 tensile testing and ISO 178:2019 flexural testing. Magnetic parameter measurement uses IEC 60404-5:2015 for individual rings, with the component fixture calibrated against a reference magnet. Thick-section rings up to 6 mm require controlled cooling to prevent sink marks on the magnet surface. The mould temperature setpoint is higher than that used for unfilled PA12 to improve skin crystallinity and dimensional accuracy. A wear-resistant shut-off valve on the injection side prevents back-flow because the compound contains a high concentration of hard ferrite particles. Screw recovery is slower than unfilled PA12 because of filler-induced viscosity; this lower screw speed is a stabilisation measure to avoid screw and barrel wear rather than a processing defect. After demoulding, the ring is conditioned at 23 °C and 50 % RH before magnetisation. Pole count is verified with a Hall sensor array and recorded per lot. Terminal products are rotor position magnet rings for brushless DC motors in industrial servos, laboratory stirrers, and compact fan drives.
In rotary-piston and turbine-type smart water meters, a ferrite-loaded PA12 rotor is overmoulded onto a stainless steel shaft and paired with a non-contact magnetic pickup. KEBABLEND MW FE 200102 PA12 is applied in this part because PA12’s low water absorption and dimensional stability reduce the risk of rotor swelling and jamming after long-term exposure to municipal water at temperatures up to 60 °C. The material is used at 100 wt% as supplied; no dilution with non-magnetisable PA12 is permitted for potable-water meter rotors because the local remanence must remain above the pickup minimum threshold. Clean process regrind from sprues may be reintroduced at a maximum of 10 wt% only for rotors that pass a full metrological batch test, including low-flow and high-flow calibration. Potable water contact candidates require lot-specific testing under DVGW W270 and the relevant national evaluation criteria for plastics in contact with drinking water; approval status must be confirmed for the specific finished rotor design before series production. The final meter assembly is tested under ISO 4064-1:2014 for cold potable water meters and ISO 4064-2:2014 for metrological performance. Electromagnetic compatibility of the pickup is assessed under EN 61000-6-2:2005 and EN 61000-6-3:2007. Restricted substance control follows RoHS Directive 2011/65/EU and REACH Regulation (EC) No 1907/2006 Article 33. Two-shot insert moulding is used, with the stainless steel shaft preheated to 80–120 °C and located in a wear-resistant mould insert. The compound is dried to below 0.10 % moisture and processed from a dry-air hopper because magnetic water meter rotors are thin in the blade region and susceptible to splay. Cavity pressure is monitored to maintain uniform packing across the rotor body. After cooling, the component is demoulded and then magnetised as a two-pole radial magnet; the magnetising fixture is centred on the shaft to avoid eccentricity-induced signal asymmetry. The rotor is checked for runout and magnetised field strength at multiple angular positions. Terminal products are magnetically coupled impeller rotors for smart water meter registers and flow-rate pickup units.
Washing machine drum speed sensor target wheels operate in a damp, mildly alkaline detergent environment and are exposed to spin-cycle vibration. The polyamide 12 matrix in KEBABLEND MW FE 200102 PA12 is less hygroscopic than short-chain polyamides, making it suited for this application where dimensional change with moisture must be controlled. The grade is processed at 100 wt% as supplied; regrind inclusion is limited to 5 wt% because detergent stress cracking in hot water is accelerated by filler-poor regrind regions. Dilution with unfilled PA12 is not recommended; if a moulder needs lower viscosity, tool-gating redesign is preferred over material lean-off because magnetic output is directly proportional to filler concentration. Household appliance components must satisfy IEC 60335-1:2020 and the relevant part IEC 60335-2-7:2019 for washing machines. Material marking uses ISO 11469:2016. Restriction of hazardous substances uses RoHS Directive 2011/65/EU Annex II and REACH Regulation (EC) No 1907/2006 Article 33. Condensation water and detergent resistance is evaluated according to ISO 175:2010 immersion test at 60 °C in a reference detergent solution. The target wheel is normally overmoulded around a metal hub or formed as a direct-mounted disc. Pre-drying uses a dehumidified-air dryer at 80 °C for 4–6 h until residual moisture falls below 0.10 %. The injection moulding screw uses wear-resistant surface treatment, and barrel temperatures are maintained within the supplier-specified profile. Mould temperature is held at 70–80 °C to reduce post-shrinkage and improve pole-pitch stability. After demoulding, the part is magnetised with a multi-pole fixture, and the output waveform is checked with a Hall sensor at the intended air gap. Components exposed to hot-water spray are subjected to an additional 500 h ageing test at 60 °C in 0.2 % detergent solution before final magnetic verification. Terminal products are drum speed sensor target wheels in direct-drive washing machines and washer-dryer combos.
When traction motor rotor hubs are overmoulded with a multi-pole encoder sleeve, rapid temperature changes from ambient to continuous operating conditions up to 120 °C with short-term excursions to 140 °C can relax moulded-in stress and shift outer diameter enough to alter the air gap between the encoder sleeve and the Hall sensor. KEBABLEND MW FE 200102 PA12 is selected when the encoder sleeve must be overmoulded onto a steel rotor hub and then magnetised to form a multi-pole outside track. The grade is processed at 100 wt% as supplied. Process regrind is restricted to 5 wt% and only for non-safety-critical programme lines because repeated thermal histories raise filler-matrix interfacial degradation and reduce magnetic reproducibility. Automotive traction motor programmes require PPAP level 3 documentation according to IATF 16949:2016 clause 8.3. Heat-ageing resistance is evaluated in a dry oven at 140 °C for 1000 h with residual induction measured in the component fixture; acceptance criteria are defined by the OEM material specification. Tensile and flexural properties are determined by ISO 527-2:2012 and ISO 178:2019. Dimensional stability is checked after conditioning under ISO 291:2008, and material marking uses ISO 11469:2016. RoHS Directive 2011/65/EU and REACH Regulation (EC) No 1907/2006 Article 33 apply. Insert overmoulding requires the steel sleeve to be preheated to 120–150 °C to reduce quench stress in the PA12 layer. The mould is vented under vacuum to prevent gas traps caused by residual monomer or moisture. Injection speed is moderate because high shear during filling aligns the ferrite particles and creates anisotropic remanence that is not desired in an encoder sleeve unless the magnetising fixture is tuned to that orientation. After demoulding, the sleeve is post-conditioned at 80 °C for 2 h to stabilise crystallinity before magnetisation. The magnetising fixture is designed to orient the magnetic field perpendicular to the outer surface through the entire wall thickness. A full-traceability lot report records peak magnetiser voltage, field strength, sleeve runout and pole-pitch accuracy. Terminal products are multi-pole encoder sleeves for rotor position sensing in electric axle drive motors, traction motors, and mild-hybrid belt-integrated starter generators.
In linear position sensing for hydraulic and pneumatic actuators, a ferrite-loaded PA12 carrier strip is injection-moulded and then magnetised with a multi-pole linear magnetic track. KEBABLEND MW FE 200102 PA12 is used when the magnet carrier must be mounted onto a moving piston rod or external linear guide. The grade is processed neat at 100 wt% as supplied. Regrind is not permitted for linear sensor tracks because repeated heat exposure causes local remanence drift along the pole path. If a lower-cost carrier is required, the compacted track is shortened rather than diluted; output stability at addition ratios below 90 wt% of this compound in the carrier has not been verified. Linear position sensors on industrial machinery report under ISO 12100:2010 safety risk assessment and IEC 61000-6-2:2005 EMC immunity. Material marking uses ISO 11469:2016. Restricted substances in the European Economic Area use REACH Regulation (EC) No 1907/2006 Article 33 and RoHS Directive 2011/65/EU Annex II. Flexural modulus is determined by ISO 178:2019; tensile strength and elongation by ISO 527-2:2012. The carrier is injection-moulded using an abrasion-resistant barrel and screw because the ferrite filler in the PA12 matrix causes greater wear than glass-fiber-reinforced compounds. Pre-drying is executed at 80 °C until residual moisture is below 0.10 %. Mould temperature is held at 70–80 °C. The component is cooled uniformly to prevent warpage in the long axis. Magnetisation is performed as a linear array of alternating poles, with the fixture moving relative to the carrier; pole pitch is measured by a Hall linear encoder and compared with the CAD reference. If the carrier is mounted on a steel piston rod, ferromagnetic interference requires compensation in the magnetising fixture. Terminal products are linear magnetic encoder carriers for hydraulic cylinder position sensors, pneumatic slide position feedback, and material handling gantry axes.
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Barlog Plastics KEBABLEND MW FE 200102 PA12 for Magnetic Components is a polyamide 12-based injection-moulding compound within the KEBABLEND magnetic filler series. The designation MW places the material in the magnetically filled product family, FE indicates an iron-bearing filler system, and 200102 is the supplier-specific formulation code. The compound is intended for net-shape production of magnetically detectable or magnetizable components such as encoder wheels, sensor carriers, actuator inserts, and small rotor bodies. Because the base resin is PA12 according to ISO 1043-1:2011, the matrix exhibits lower equilibrium moisture uptake than PA6 and PA66; however, the filled compound’s processing behaviour is governed primarily by the iron-bearing filler volume fraction.
The supplier datasheet defines the exact filler chemistry and loading; published data for the magnetic filler fraction in MW FE 200102 is limited. The unfilled PA12 matrix typically has a density of 1.01 g/cm³ to 1.04 g/cm³ when measured according to ISO 1183-1:2019. The compounded magnetic grade exhibits a higher density because iron-bearing particles dominate the inorganic phase; density values in comparable PA12 magnetic compounds are commonly above 2.5 g/cm³, but the exact value must be taken from the supplier certificate of analysis rather than inferred from generic datasheets. Shrinkage behaviour cannot be assumed from unfilled PA12 data. Mould shrinkage in flow and transverse directions must be measured on test plaques according to ISO 294-4:2018 because filler orientation created by the melt-flow field produces anisotropic shrinkage and part distortion.
The material is not supplied with food-contact or medical-grade documentation. No FDA 21 CFR clearance should be assumed unless explicitly stated on the supplier regulatory datasheet. The magnetic filler may also limit recyclability in transparent PA12 rework streams because metal contamination can damage pelletizing blades and hot-runner tips.
| Requirement | Standard or regulation | Application note |
|---|---|---|
| Base polymer designation | ISO 1043-1:2011 | PA12 |
| Density | ISO 1183-1:2019 | Method A, immersion |
| Tensile properties | ISO 527-1:2019 / ISO 527-2:2012 | Test specimen 1A |
| Flexural properties | ISO 178:2019 | 3-point bending |
| Charpy impact | ISO 179-1:2020 | Notched, edgewise |
| Heat deflection temperature | ISO 75-1/-2:2020 | 1.8 MPa |
| Melt volume-flow rate | ISO 1133-1:2022 | Comparative only |
| Magnetic hysteresis | IEC 60404-4 | Part-level or ring-core fixture |
| Hazardous substances | 2011/65/EU | Supplier declaration required |
| REACH | 1907/2006 | SVHC threshold not assumed |
Production-scale injection moulding of iron-filled PA12 requires a low-compression screw, hardened check ring, and shut-off nozzle to prevent melt drool from the highly filled system. On all-electric injection moulding machines with screw diameters from 18 mm to 30 mm and clamping forces from 400 kN to 1200 kN, the compound is typically processed with a barrel temperature profile rising from 220 °C in the feed zone to 250 °C at the nozzle. Melt temperature should not exceed 260 °C; residence time above 250 °C should be limited to 5 min to 10 min to avoid thermal degradation of the PA12 matrix and surface oxidation of the filler. Mould temperatures between 60 °C and 100 °C improve crystallinity and reduce sink marks but extend cycle time. Back pressure should be held between 10 bar and 20 bar to maintain homogeneous melt temperature without excessive shear heating that can reduce magnetic response by breaking filler particles. Shot size should not exceed 60 % of barrel capacity.
Because the density of the final part is a direct function of filler loading, part weight should be monitored as a first-pass quality-control check. In multi-cavity tools, a weight deviation above ±1.5 % between cavities can indicate filler segregation, inconsistent shot volume, or moisture variation, all of which can alter magnetic output. The melt cushion should be held stable; a fluctuating cushion below 2 mm can produce short shots and unmelted solid-bed material entering the cavity.
Iron-bearing fillers raise the low-shear viscosity relative to unfilled PA12. When the filler volume fraction approaches a percolation threshold, the melt transitions from a polymer-dominated flow field to a particle-network flow field, increasing injection pressure and reducing flow length. For PA12 magnetic compounds, the practical processing response is that thin walls below 0.8 mm should be validated with short-shot studies rather than predicted from unfilled PA12 spiral-flow data. The melt volume-flow rate measured according to ISO 1133-1:2022 is only a first-pass comparator; it does not capture the shear-thinning and wall-slip behaviour of highly filled magnetic compounds. Gate design should avoid needle gates smaller than 1.0 mm because filler accumulation at the gate can create pressure spikes and gate freeze-off before the cavity is packed. Hot-runner systems with externally heated manifolds and tip diameters of at least 1.2 mm are preferred, but the supplier technical datasheet for MW FE 200102 should be consulted because magnetic filler can accelerate tip wear.
Dispersion quality of the iron-bearing filler is not automatically guaranteed by the compound supplier. Excessive screw speed and high back pressure can break filler particles and reduce the mean particle size, shifting the magnetic hysteresis loop and lowering remanence. Conversely, low back pressure can allow filler agglomerates to survive plastification, producing surface defects and local flux dead spots. The recommended screw speed for a 25 mm screw is generally in the range of 80 rpm to 150 rpm, but the exact setting must be adjusted to the screw design and L/D ratio. For a general-purpose screw with L/D of 20:1 to 22:1, higher speeds may introduce unacceptable shear heating; for a barrier screw with L/D of 25:1, the shear history is longer and the speed limit may be lower.
Magnetic validation should not terminate at the granule level. The remanence, coercivity, and maximum energy product of a polymer-bonded magnet are geometry-dependent. For injection-moulded parts, B-H hysteresis is measured on finished components or standardized test rings, not on raw compound pellets. The relevant measurement framework for magnetic materials is IEC 60404-4, but injection-moulded parts often require application-specific fixtures because standard Epstein frames and ring cores do not match the final part geometry. Published magnetic data for this specific configuration is limited; part-level flux mapping or torque measurement under the intended operating field strength and frequency is required for first-article approval. At frequencies above 10 kHz, eddy-current shielding and hysteresis losses can reduce the effective permeability of the part, even when the iron-bearing filler itself has suitable intrinsic permeability; the threshold depends on particle size and interparticle insulation.
Pre-drying is required for PA12 magnetic compounds. The equilibrium moisture content of PA12 at 23 °C and 50 % RH is typically 0.5 % to 0.8 %, lower than PA6 at 2.5 % to 3.0 % under identical conditions. However, moisture levels above 0.1 % can produce hydrolysis during melt processing, causing splay, reduced molecular weight, and inconsistent filler wetting. The compound should be dried with a desiccant dryer at 80 °C to 90 °C for 4 h to 8 h to a residual moisture target below 0.1 %. Hot-air ovens are less suitable for iron-filled grades because uneven heating can create localized oxidation of filler surfaces and batch-to-batch variation in magnetic response. If the granulate is stored in non-sealed hoppers at relative humidity above 60 % RH, it should be re-dried before processing even if the original moisture content was within specification.
Residual moisture should be measured according to ISO 15512:2019 or equivalent; infrared moisture balances can give biased readings because the iron-bearing filler can oxidize and add weight during heating. The target residual moisture below 0.1 % should be verified on granulate drawn from the bottom of the dryer hopper, not from the top. Batch-to-batch variation in PA12 magnetic compounds is most commonly observed in melt viscosity and filler loading. Incoming inspection should include melt volume-flow rate per ISO 1133-1:2022, ash content per ISO 3451-1:2019, and density per ISO 1183-1:2019. If ash content varies by more than ±0.5 % absolute, the magnetic filler loading has shifted enough to affect part weight and possible magnetic output.
Hygrothermal aging after moulding affects mechanical properties rather than intrinsic magnetic properties. PA12 absorbs moisture over time, reducing glass transition temperature and stiffness. For magnetic components that are press-fitted onto shafts or overmoulded onto metal inserts, moisture swelling can relax the press-fit and alter the air gap. Designers should evaluate the part after conditioning to equilibrium moisture rather than on dry-as-moulded samples. A common conditioning protocol is storing the part at 23 °C and 50 % RH until mass change stabilizes, then repeating the dimensional and flux measurements.
The material differs from unfilled PA12 and PBT-based magnetic grades in three operational dimensions. First, relative to unfilled PA12, the magnetic grade has higher density, higher thermal conductivity, and lower notched impact strength because the rigid filler concentrates stress at the matrix interface; Charpy impact values should be measured according to ISO 179-1:2020 on the final part thickness, not extrapolated from unfilled PA12 standards. Second, relative to PA6-based magnetic grades, the PA12 matrix maintains a lower equilibrium moisture uptake and therefore shows less moisture-induced dimensional change and less shift in stiffness after prolonged exposure to humid air. Third, relative to PPS-based magnetic grades, the PA12 version has a lower continuous-use temperature ceiling; PPS magnetic compounds often carry an RTI above 220 °C according to UL 746B, whereas PA12 formulations are typically rated below 120 °C. This restricts MW FE 200102 to non-high-temperature applications such as automotive interior sensors, consumer actuators, and industrial encoders rather than under-hood high-temperature locations.
In a moulded encoder wheel or rotor insert, the measured magnetic field at the air gap depends on part wall thickness, filler alignment, internal stress, and the shape of the magnetic poles. Unfilled PA12 shrinkage would hide the effect of filler loading; therefore tool trials must include cavity pressure sensors and thermocouples to separate material shrinkage from mould temperature drift. In multi-cavity tools, filler orientation can vary between cavities if the gate locations and flow lengths differ, producing part-to-part variation in magnetic output even when the granulate lot is unchanged. The compound should be qualified on the production tool using the same gate type, wall thickness, and cooling rate intended for series production. If the tool uses hot-runner valve gates, the shear history at the gate can align high-aspect-ratio iron particles in the flow direction, increasing magnetic anisotropy in the gate region and potentially reducing flux at the part perimeter. This effect is quantified by magnetic pole mapping; published data for this specific configuration is limited, and no generic datasheet value can replace tool-specific testing.
After demoulding, magnetizable components may be magnetized in a fixture that applies a pulsed field or magnetostatic field. The magnetization field required depends on the intrinsic coercivity of the iron-bearing filler and the shape anisotropy of the moulded part. Published data for this specific configuration is limited; the supplier should provide the recommended magnetizing field for MW FE 200102. Magnetizing before the part has cooled to ambient temperature can be less stable because thermal demagnetization increases with temperature. The part should be allowed to reach ambient temperature after demoulding before magnetization, and the magnetization fixture should be designed to minimize air gaps between the coil and the part surface. For multi-pole encoder wheels, the magnetizing head should be verified with field mapping on every cavity because the pole shape depends on both the magnetizing coil and the local filler orientation.
Thermal conductivity of iron-filled PA12 is higher than unfilled PA12, which is beneficial for dissipating heat from rotor assemblies but complicates cooling-time prediction. Thermal conductivity should be measured on a moulded plaque according to ISO 22007-2:2015 because the filler orientation and skin-core structure create anisotropy. Cooling time calculations based on unfilled PA12 thermal diffusivity may overestimate cycle time and produce part warpage from excessive packing. Flatness tolerance must be established on the production tool; no generic datasheet value applies because flow-direction and transverse-direction shrinkage differences are tool-specific.
Failure modes observed on production lines for iron-filled PA12 are dominated by filler abrasion and feed-throat compaction. The feed throat must be cooled to prevent premature melting and bridging of granulate that contains high-density filler. Use a feed throat temperature of 40 °C to 60 °C and verify that the hopper magnet is cleaned regularly because iron-bearing granulate can form magnetic bridges. During production interruptions, the hot-runner manifold should be maintained at melt temperature but the screw should be retracted and the nozzle purged. Idle times longer than 10 min at full melt temperature can allow filler settling in the melt channel and create a variable-density melt front. On restart, the first 3 to 5 shots should be discarded or regrind-limited until shot weight and flux mapping stabilize.
Iron-bearing fillers in PA12 compounds are not inherently protected from corrosion if the polymer matrix is breached. Scratched surfaces, microcracks around inserts, or exposed filler particles at the gate can oxidize in humid or salt-laden environments. Salt-spray testing according to ISO 9227:2017 is recommended for components with exterior exposure. If the application requires corrosion resistance, a secondary protective coating may be needed, but adhesion to PA12 magnetic compounds must be validated because the high filler content can reduce surface energy and coating wetting.
Regrind use in magnetic components should be restricted. Filled PA12 regrind fed back into the process can increase melt viscosity variation and raise the risk of filler agglomeration after repeated heat histories. If regrind is used, the ratio should not exceed 20 % by mass and should be dried with the same residual moisture target below 0.1 %. Higher regrind fractions can reduce mechanical toughness and shift the apparent density due to filler loss during grinding and dust extraction. Production trials should include magnetic flux measurement on parts made with 0 %, 10 %, and 20 % regrind to establish the upper control limit for the specific part geometry.
Storage in sealed bags is required. Opened bags should be resealed and kept in a dry area at 10 °C to 30 °C. High storage temperatures above 50 °C can accelerate oxidative degradation of the PA12 matrix over extended periods and may shift the surface condition of the iron-bearing filler. The supplier safety data sheet should also be reviewed for nickel, cobalt, or other alloying elements if the iron filler is an alloy rather than a pure iron powder; RoHS compliance for lead, mercury, cadmium, hexavalent chromium, PBB, and PBDE is expected under 2011/65/EU but must be confirmed on the final part.
