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Hybrid layered manufacturing, an automatic layered manufacturing process for metallic objects, combines the best features of two well-known and economical processes, namely, weld-deposition and milling. A study of the mechanical properties like hardness and tensile strength of objects made through hybrid layered manufacturing is presented in this article. It was found that the interior matrix has negligible hardness variations in all directions. The tensile strength of the matrix displays negligible variations in the horizontal plane. However, the same for the vertical direction initially was found to be slightly lower, but this could be rectified by increasing the weld-deposition current. The ability of hybrid layered manufacturing to make composite material matrix with good material bonding has also been demonstrated. These studies help in understanding and controlling the anisotropic behavior of objects built using weld-deposition–based rapid prototyping and manufacturing techniques.

Additive manufacturing via 3-D printing technologies have become a frontier in materials research, including its application in the development and recycling of permanent magnets. This work addresses the opportunity to integrate magnetic field sources into 3-D printing process in order to enable printing, alignment of anisotropic permanent magnets or magnetizing of magnetic filler materials, without requiring further processing. A non-axisymmetric electromagnet-type field source architecture was designed, modelled, constructed, and installed to a fused filament commercial 3-D printer and tested. The testing was performed by applying magnetic field while printing composite anisotropic Nd-Fe-B+Sm-Fe-N powders bonded in Nylon12 (65vol.%) and recycled Sm-Co powder bonded in PLA (15vol.%). Magnetic characterization indicated that the degree-of-alignment of the magnet powders increased both with alignment field strength (controlled by the current applied to the magnetizing system) and the printing temperature. Both coercivity and remanence were found to be strongly dependent on the degree-of-alignment except for printing performed below but near the Curie temperature of Nd-Fe-B (310°C). Under applied field of 0.15 kOe, Sm-Co and hybrid Nd-Fe-B/Sm-Fe-N printed samples showed degrees-of-alignment of 83% and 65%, respectively. The variations in coercivity were consistent with previous observations in bonded magnet materials. This work verifies that integration of magnetic field sources into 3-D printing processes will result in magnetic alignment of particles while ensuring that other advantages of 3-D printing are retained.

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