Magnetics – The Future of Workholding

For decades, magnetic workholding was considered a niche solution—ideal for flat plate materials on surface grinders, but rarely trusted beyond that. Today, however, the landscape of modern machining is changing rapidly. Thanks to major advancements in magnetic technology, magnets are now proving to be a powerful and flexible solution across a much broader range of general metalworking processes—especially milling and turning.

At 1st MTA, we believe it’s time to take a fresh look at what magnetic workholding has to offer. Whether you’re seeking faster setups, improved tool access, or enhanced safety, magnetics might just be the upgrade your workshop needs.

Beyond Flat Plates – The Magnetic Advantage

Magnetic workholding is no longer limited to flat components or light machining operations. New developments in electro-permanent magnetic systems now enable:

• Edge and through milling
• Through drilling and tapping
• Single-setup turning for rings and round parts
• Fixture-free clamping of irregular parts

This flexibility makes magnetics ideal for a wide variety of production scenarios, from short-run prototyping to full-scale manufacturing.

Breaking the Myth: Are Magnets Strong Enough for Milling?

One of the biggest concerns machinists have is whether magnets can reliably hold parts under heavy machining conditions. The answer is a resounding yes—when properly applied.

Modern magnetic chucks utilise rare earth neodymium iron boron—a material up to five times more powerful than previous magnet technologies. These compact yet incredibly strong magnets offer holding forces that rival, and often exceed, those of mechanical clamps—while providing consistency and reliability that’s hard to match.

Why Magnetic Workholding Makes Sense

✔ Consistent Clamping Force

With magnets, the clamping force is either on or off—eliminating operator variation and ensuring repeatability. Electro, electro-permanent, and even permanent magnetic systems can often regulate this force from 0% to 100%.

✔ Full-Surface Contact

Unlike mechanical clamps that apply force at discrete points, magnets distribute clamping force across the entire contact surface of the workpiece. This not only minimises vibration and chatter, but also allows for faster and more stable machining.

✔ Better Tool Access

With no clamps obstructing the edges, you can machine more of the workpiece in a single setup. This opens up more aggressive machining strategies, reduces repositioning, and simplifies programming.

✔ Versatile Applications

Nearly any ferromagnetic material can be held magnetically—as long as one surface is reasonably flat and large enough to cover at least two magnetic poles.

✔ Faster Setup and Breakdown

Magnetic systems offer the fastest clamp/unclamp cycle of any workholding method. No bolts, no alignment tools—just place the part and switch on the magnet. When used as a base plate, magnets can also secure vices or fixtures in seconds, enabling lightning-fast changeovers.

✔ Energy Efficient and Low Maintenance

Electro-permanent magnets require power only for activation or deactivation, consuming virtually no energy during operation. With no moving parts, magnets are inherently reliable and require minimal maintenance.

✔ Maximum Safety

Electro-permanent technology combines the strength of electromagnets with the safety of permanent magnets. If power is lost, the magnet stays active, ensuring fail-safe clamping.

What About Chip Control and Magnetic Flux?

A common technical consideration is how magnetic flux affects the workpiece. When the flux penetrates the material, it can cause the top of the part to attract chips. However, this is easily controlled using pole extenders or stand-offs to adjust how deeply the magnetic field penetrates. Some systems even allow fine-tuning of magnetic pull strength to optimise performance.

Magnetics for Turning – One Setup, More Machining

Magnetic workholding isn’t just for milling. It also offers huge benefits for turning. For example, when machining a ring-shaped part, traditional chucks require clamping on the ID or OD—and repositioning to machine all features. With a magnetic chuck, you can grip the entire part face in one go, machining ID, OD, and front face in a single setup. This significantly reduces cycle times and boosts precision.

Could Magnetic Workholding Be Right for You?

Ask yourself:

• Are you machining ferromagnetic materials?
• Do you need to machine multiple sides of a part?
• Do you want faster setups for vices and fixtures?
• Are you trying to reduce machine downtime?

If the answer is “yes” to any of these, magnetic workholding could be a game-changer for your operations.

And remember, modern magnetic systems aren’t just for large flat parts. Pole spacing is now so fine that even smaller components can be held safely and securely. And if you’re working with non-ferrous materials, magnets can still help by holding the fixtures or vices that grip those components.

Magnetic Workholding – Principles to Keep in Mind

• Magnetic flux always takes the shortest path.
• Flux is weakened by air gaps and non-conductive materials.
• Every north pole needs a matching south pole for the circuit to close.
• Flux should be concentrated at the contact surface, not dispersed.
• Material type affects clamping strength—low permeability materials hold less securely.
• Material condition matters—annealed steels absorb flux better, while hardened materials may retain residual magnetism after use.

Conclusion: Better, Safer, Smarter Workholding

Magnetic workholding is not just a trend—it’s a modern, proven solution for 21st-century machining. It reduces downtime, boosts throughput, and increases machining flexibility while enhancing safety and reliability.

At 1st MTA, we’re here to help you explore the full potential of magnetic workholding systems—from application advice to product selection. Whether you’re milling, turning, or drilling, magnetic technology can unlock new efficiencies and capabilities for your shop.