Development of a Magnetic Levitation System for Additive Manufacturing: Simulation Analyses

Abstract

Magnetic levitation has been always a very promising field. Due to its versatility, it has garnered interest in fields energy harvesting, high speed transportation and high precision micro-manipulation amongst other fields. However, it's application within the sphere of Additive Manufacturing (AM) has been negligible. Thus, for the first time, the work conducted here works with the development of a novel technique utilizing magnetic levitation for stable suspension for AM. Current AM technique are heavily dependent on the building the part on a substrate. The substrate limits the use of multiple material nozzles and also requires significant post-processing. The use of the principle of magnetic levitation can bypass the need for this substrate. Primary emphasis is placed on computation of eddy currents and Lorentz force produced from the magnetic levitation system and also on finding the relevant parameters affecting several output parameters like position of levitation, force experienced by the object suspended etc. A temperature analysis is also conducted to ensure that the principles used here are valid. ANSYS Ansoft Maxwell Modules are used to determine these input parameters. The work is subsequently validated through the transient module of the same module. The results presented here depict the viability of the system within the AM environment and the successful elimination of the need for a substrate.

Experimental Implementation of a Magnetic Levitation System for Laser-Directed Energy Deposition via Powder Feeding Additive Manufacturing Applications

“…The system is made up of two concurrent coils that carry currents in opposite directions and are embedded within a high-permeability material (referred to as the core). The working principle has been highlighted in previous articles [17,18].…”

Development and Analysis of a Novel Magnetic Levitation System with a Feedback Controller for Additive Manufacturing Applications

“…The working principle has been described in our previous work [16,17]. It is discussed here as well.…”

“…For the position feedback controller, a relationship between the input current and the output force was developed using the principle of curve fitting, keeping the position of the disc constant. The developed relationship was then used to calculate the lift current, i.e., the minimum RMS current required to stably levitate the disc at a given position [16]. The lift current was calculated for positions from 1-10 mm above the levitator, with a sample plot shown in Figure 18A.…”

“…We have taken a different approach, using two coils carrying current in opposite directions to facilitate stable suspension of a levitated disc and discussing the initial viability of the approach [16]. We subsequently developed a novel levitation system with the prime point of emphasis being placed on compatibility with AM operations.…”

Design and Fabrication of a Magnetic Actuator for Torque and Force Control Estimated by the ANN/SA Algorithm

“…Electromagnetism principles and magnetic actuators have been implemented in various applications such as metal forming, where a solenoid with 15 turns generates a magnetic force to push a light metal in order to form a cellphone case [1], real-time production of magnetic materials with the 3D printer in additive manufacturing is feasible by aligning the particles with the magnetic field [2]. In addition, magnetic levitation can be used to design a stable suspension for metal additive manufacturing, which results in substrate elimination [3]. For biological purposes, the electroless plating technique has been used to make magnetic microparts that can rotate at high speed using a magnetic actuator for functional lab-on-a-chip devices [4].…”