The effects of the compaction step on the (micro)structural features and aging behavior of polymer coated NdFeB-based bonded magnets is reported. Due to the fracture of the material during pressing, it is estimated an increase of at least 14% in the particles' area which is not coated. Such uncoated surfaces, when exposed to the environment, reduce the magnetic performance of the magnets aged/cured in air by 19% in the conditions evaluated in this investigation. Furthermore, XRD results interpreted by Rietveld analyses show a lattice parameter change in the tetragonal structure of the hard magnetic phase after pressing. Such change varies as a function of the height of the compacted part and it is ascribed to macro-elastic stress arising from the pressure distribution in the magnet. An aging/curing step during 24 h is able to relief such macro-elastic stress. (C) 2012 Elsevier B.V. All rights reserved.