Can I cut, drill or machine magnets to my own sizes and shapes?
Yes and no. AlNiCo magnets are very easy to machine in any way you wish. NdFeB magnets are by nature very hard and brittle. Although they can be cut, drilled and machined, it should ONLY be done by folks who are experienced with ceramics. If the magnets get over about 300 deg F, they will lose their magnetism permanently. They are flammable, and it is not difficult while grinding or machining to get them (or the chips and dusts from cutting) so hot hot they ignite. If they do ignite, the fumes are toxic and the material burns very fast and hot, like Magnesium! In our experience any machining of these magnets should be done with diamond tools under lots of coolant with good ventilation and the risk of fire in mind.