Additive Manufacturing of Highly Aligned Nd-Fe-B Bonded Magnets

The fabrication of anisotropic magnets through 3D printing presents challenges in achieving both high magnetic alignment and complex geometries. This research addresses these challenges by developing a novel 3D printing process based on the direct-ink-writing technique for the fabrication of highly aligned Nd-Fe-B bonded magnets. The material used is a composite of anisotropic Nd-Fe-B powders suspended in a UV-curable resin. To ensure optimal magnetic alignment, a Halbach array generating a magnetic field strength of approximately 2 Tesla is employed during the printing process. The Halbach array is seamlessly integrated into the 3D printing system to achieve high alignment of the anisotropic powder while ensuring no adverse effects on the extrusion process. A specially designed UV curing module is integrated to rapidly solidify the resin post-deposition, enabling the creation of intricate 3D structures without compromising the magnetic alignment. This innovative process successfully combines the production of highly aligned magnetic materials with the flexibility of 3D printing, offering new possibilities for the fabrication of complex magnetic structures. Additionally, I will discuss how this technology can be expanded to various applications, including sensors, actuators, and other electromechanical devices, and explore the potential for future innovations in 4D printing to create dynamic, responsive magnetic structures.