Investigating the use of 3D printed soft magnetic PEEK‐based composite for space compliant electrical motors

Abstract

Electric motors are ubiquitous on spacecraft and their smooth operation relies on the presence of naturally magnetic materials. The employment of conventional metal-based magnets causes some inconveniences such as high values of specific gravity and the limited reproducibility of complicated geometries. The introduction of novel polymer-based magnetic materials processed via additive manufacturing represents a brilliant answer to these needs. This paper describes the first-time development of a polyether ether ketone-magnetite (Fe 3 O 4 ) soft magnetic composite. The material was prepared by adding 50 wt% magnetic microparticles to the polymeric matrix. The composite material was extruded in form of filaments and 3D printed via fused filament fabrication.

3D Printing Soft Magnet: Binder Study for Vat Photopolymerization of Ferrosilicon Magnetic Composites

“…In contrast, the composite at 64 v / v % exceeded the predicted percolation threshold, leading to the 206.77% increase in saturation magnetization. This result suggests that the magnetic particles in the 64 v / v % composite were close enough to form interacting percolating clusters [ 64 , 65 ], while at 64 v / v %, there were still voids and gaps between the magnetic particles, which likely caused a reduction in the average exchange and dipolar interactions and resulted in lower saturation magnetization values compared to bulk Fe-6.5 wt%Si (1353 emu/cm 3 ) [ 66 , 67 ].…”