Magnetically Functional Materials: Design and 3D Printing

3D printing has revolutionized the manufacturing landscape by offering unparalleled design flexibility, rapid prototyping, and the ability to produce small batches of customized components. In the same vein, development of magnetic bonded materials has opened new possibilities for the customization and fabrication of magnetic structures with potential applications in various industries, including automotive, aerospace, and medical devices. However, challenges remain in the field of 3D printing of magnetic materials, such as producing small quantities, customized designs and developing reliable fabrication methods for hard magnetic materials.

Fused filament fabrication (FFF) 3D printing presents a promising solution to these challenges, as it enables the creation of intricate structures with tailored magnetic properties. Despite its potential, there is currently no commercial hard magnetic filament available. To address this gap, we developed a custom filament with various filling factors by using ABS as an effective binder for the hard magnetic particles. This approach allowed us to achieve precise control over the magnetic properties and optimize the performance of the printed components.

As a proof of concept showing the versatility and utility of our custom hard magnetic filaments, we designed, and 3D printed a passive shimming system in a Halbach array configuration to improve the magnetic field homogeneity. This application showcases the potential of our filament for producing complex magnetic structures with tailored properties, which could lead to advancements in a wide range of industries that rely on magnetic materials.

Additionally, a near-room-temperature magneto-responsive elastomer within the context of soft robotics was developed. The elastomer exhibits unique actuation properties, combining the advantages of magnetically and thermally responsive actuators, with potential applications in a wide range of industries. By employing specific types of soft magnetic materials, and mixing them with silicone rubber, a thermo-magneto actuator with a low responsive temperature was created. The study incorporated finite element modeling and experimental data to understand the elastomer's behavior, providing a foundation for future research in soft robotics applications.

In summary, our work highlights the great potential of 3D printing for the development of hard magnetic materials and demonstrates the potential of FFF 3D printing to create customized magnetic components and addresses fabrication challenges in various applications.