3D printing of polymer-bonded magnets from highly concentrated, plate-like particle suspensions

Shen, Alan; Peng, Xiaoguang; Bailey, Callum; Dardona, Sameh; Anson, W. K.

doi:10.1016/j.matdes.2019.108133

Cited by 33 publications

(33 citation statements)

References 33 publications

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“…31,35,36 To take advantage of the Farris effect for DIW, bimodal formulations of polymer-bound alumina have been printed 23 and up to a 65 vol% solid loading was achieved by using UV-assisted DIW to print bimodal inks of polymer-bound neodymium magnets. 27 Although these results are encouraging, they report on optimized inks and do not investigate the impact of the bimodal distribution on the printability of highly loaded inks or the influence of the binder system selected for the carrier material. A broad base of understanding of how material and process parameters impact printability and shape fidelity for high solids inks is necessary to enable design of new inks for the myriad application areas interested in high solids AM.…”

Section: Introductionmentioning

confidence: 99%

Direct ink write 3D printing of high solids loading bimodal distributions of particles

et al. 2021

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As additive manufacturing (AM) expands as a processing technology for structurally customizable materials, there is increasing interest in printing with high particle contents. For suspensions with particle contents of over 50 vol%, there are significant formulation and processing challenges due to increased interparticle friction and suspension complexity. We focus on suspensions with bimodal particle distributions and two common binder systems, a high molecular weight polymer in a solvent that solidifies via solvent evaporation and a monomer mixture that cures via ultraviolet irradiation. We examine the interplay between formulation and processing and show that the formulation effects are particularly important at optimal printing parameters, but that they are overcome by processing-related defects at sub-optimal parameters. By understanding the processing and formulation effects specific to direct ink write AM of high solids suspensions, new customized inks can be designed for a wide range of applications, including construction, energetics, and ceramics.

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Section: Introductionmentioning

confidence: 99%

Direct ink write 3D printing of high solids loading bimodal distributions of particles

et al. 2021

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“…It is known that the particle size and shape can affect the viscosity of the bonded magnets. [19,20] For example, the orientation of the high aspect ratio particles affects the overall viscosity of the system since the particles tend to align along the shear plane. It is reported that the viscosities of non-spherical Nd-Fe-B suspensions are generally higher than the viscosities of spherical Nd-Fe-B suspensions.…”

Section: Microstructurementioning

confidence: 99%

“…It is reported that the viscosities of non-spherical Nd-Fe-B suspensions are generally higher than the viscosities of spherical Nd-Fe-B suspensions. [20][21][22] Therefore, the particle shape and size could not only affect the rheology of the binder but also the loading fraction in the polymer thereby altering the magnetic properties and thermal stability of the bonded magnets.…”

Section: Microstructurementioning

confidence: 99%

“…The saturation magnetization directly increases with higher loading of magnetic fraction and the effect of the magnetic field during alignment thereby increases the B r and M s. Several factors can affect coercivity of the bonded magnets namely the increase in dipole interaction due to high magnetic fraction content, and the variation in the degree of grain alignment leading to plausible cause for the reduction in coercivity. [20,25] Table 1 shows the magnetic properties of the anisotropic bonded magnets as a function of magnetic alignment fields. The as-printed sample has a low remanence, B r = 0.35 T, and higher coercivity, H c = 557 kA m -1 .…”

Section: Magnetic Propertiesmentioning

confidence: 99%

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Additive Manufacturing of Anisotropic Sm-Fe-N Nylon Bonded Permanent Magnets

Gandha

Paranthaman

Sales

et al. 2021

Preprint

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Fabricating a bonded magnet with a near-net shape in suitable thermoplastic polymer binders is of paramount importance in the development of cost-effective energy technologies. In this work, anisotropic Sm2Fe17N3 (Sm-Fe-N) bonded magnets are additively printed using Sm-Fe-N anisotropic magnetic particles in a polymeric binder polyamide-12 (PA12). The anisotropic bonded permanent magnets are fabricated by Big Area Additive Manufacturing followed by post-aligned in a magnetic field. Optimal post-alignment results in an enhanced remanence of ~ 0.68 T in PA12 reflected in a parallel-oriented (aligned) measured direction. The maximum energy product achieved for the additively printed anisotropic bonded magnet of Sm-Fe-N in PA12 polymer is 78.8 KJ m-3. Our results show advanced processing flexibility of additive manufacturing for the development of Sm-Fe-N bonded magnets in polymer media designed for applications with no critical rare earth magnets.

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“…A multi extruder 3D printer was utilized by Yan et al to fabricate magnetic components for power electronics applications [ 21 ]. Magnetic material formulations developed using UV curable resins were printed using nScrypt tabletop micro dispensing equipment that enabled the precise control of printed layer thickness of the deposited material [ 22 , 23 ]. Manufacturing of permanent magnets using extrusion-based AM of thermoplastic based feedstock materials has been detailed in the technical literature [ 24 , 25 , 26 , 27 ].…”

Section: Introductionmentioning

confidence: 99%

Development and Characterization of Field Structured Magnetic Composites

et al. 2021

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Polymer composites containing ferromagnetic fillers are promising for applications relating to electrical and electronic devices. In this research, the authors modified an ultraviolet light (UV) curable prepolymer to additionally cure upon heating and validated a permanent magnet-based particle alignment system toward fabricating anisotropic magnetic composites. The developed dual-cure acrylate-based resin, reinforced with ferromagnetic fillers, was first tested for its ability to polymerize through UV and heat. Then, the magnetic alignment setup was used to orient magnetic particles in the dual-cure acrylate-based resin and a heat curable epoxy resin system in a polymer casting approach. The alignment setup was subsequently integrated with a material jetting 3D printer, and the dual-cure resin was dispensed and cured in-situ using UV, followed by thermal post-curing. The resulting magnetic composites were tested for their filler loading, microstructural morphology, alignment of the easy axis of magnetization, and degree of monomer conversion. Magnetic characterization was conducted using a vibrating sample magnetometer along the in-plane and out-of-plane directions to study anisotropic properties. This research establishes a methodology to combine magnetic field induced particle alignment along with a dual-cure resin to create anisotropic magnetic composites through polymer casting and additive manufacturing.

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3D printing of polymer-bonded magnets from highly concentrated, plate-like particle suspensions

Cited by 33 publications

References 33 publications

Direct ink write 3D printing of high solids loading bimodal distributions of particles

Direct ink write 3D printing of high solids loading bimodal distributions of particles

Additive Manufacturing of Anisotropic Sm-Fe-N Nylon Bonded Permanent Magnets

Development and Characterization of Field Structured Magnetic Composites

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