Methods, materials and structures for manufacturing a magnetically actuated exciter device using 3D printing

A method for manufacturing a shaker device, the method comprising:

• forming a bobbin assembly by providing a bobbin body and winding an electric conductor on the bobbin body to form an electromagnet coil;
• providing a cylindrical body including a helical structure;
• positioning the bobbin assembly within an interior of the cylindrical body;
• positioning a piston assembly within the bobbin assembly, wherein the piston assembly includes a piston and a permanent magnet fixedly coupled to the piston, wherein the shaker device is configured to generate a force when an electrical current signal is applied to the electromagnet coil creating a controllable magnetic field that impinges the permanent magnet of the piston assembly and causes a linear movement of the cylindrical body relative to the piston assembly;
• 3D-printing a support plate, the support plate including an opening aligned to receive a portion of the piston and including an opposite helical structure configured to engage the helical structure of the cylindrical body;
• and
• positioning a radial guide bushing on the support plate coaxially around the opening before coupling a ring magnet to the support plate, wherein the radial guide bushing is coupled to the support plate by the ring magnet.

A method for manufacturing a shaker device, the method comprising:

• forming a bobbin assembly by providing a bobbin body and winding an electric conductor on the bobbin body to form an electromagnet coil;
• providing a cylindrical body including a helical structure;
• positioning the bobbin assembly within an interior of the cylindrical body;
• positioning a piston assembly within the bobbin assembly, wherein the piston assembly includes a piston and a permanent magnet fixedly coupled to the piston, wherein the shaker device is configured to generate a force when an electrical current signal is applied to the electromagnet coil creating a controllable magnetic field that impinges the permanent magnet of the piston assembly and causes a linear movement of the cylindrical body relative to the piston assembly;
• 3D printing a support plate, the support plate including an opening aligned to receive a portion of the piston and including an opposite helical structure configured to engage the helical structure of the cylindrical body;
• and
• 3D-printing a base plate that is contoured to match a surface of a device-under-test, wherein the base plate is configured to couple an end of the piston to the surface of the device-under-test while the shaker device is operated to generate a force to be applied to the device-under-test.