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The engineering requirements are stated in respect to the testing of model filters and the extrapolation sizing of full‐scale high‐gradient magnetic separators for operation in the region of high aerodynamic loading, i.e., where large process capacities are involved and hence size and pressure loss are important considerations. Problems related to the characterization of the mesh are detailed, as are the scale effects associated with the model, i.e., with regard to entrance/exit ’’losses’’ and wall‐drag/short‐circuiting phenomena. Flexure and fluidization of the mesh and constructional problems associated with the roughness (or unevenness) of the fibers are demonstrated by reference to test results from an axial‐filament cartridge. The case is made for flow‐resistance tests to be carried out in advance of trajectory studies in order first to establish the flow regime. The effect of the flow condition on such considerations as interfiber, interparticle, and fiber/particle interference is discussed along with the limitations of flow resistance and trajectory analysis as design aids.