# US 2021/0280368 A1 · Method for three-dimensional printing of magnetic materials > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2021/0280368 A1 - Document ID: US20210280368A1 - Status: Published application - Kind: A1 - Application number: 17/329,741 - Filed: 2021-05-25 - Published: 2021-09-09 - Earliest claimed: 2017-10-11 - Assignees: Ford Global Technologies, LLC - Applicants: Ford Global Technologies, LLC - Inventors: Chuanbing Rong; Feng Liang; Leyi Zhu; Michael W. Degner - Web page: https://patentgrep.com/patent/US20210280368A1 ## CPC - H01F 41/0253: {for manufacturing permanent magnets} - B05C 5/027: {Coating heads with several outlets, e.g. aligned transversally to the moving direction of a web to be coated (B05C5/0254 takes precedence)} - B22F 9/08: by casting, e.g. through sieves or in water, by atomising or spraying (using electric discharge B22F9/14) - B22F 10/00: Additive manufacturing of workpieces or articles from metallic powder (apparatus or devices therefor B22F12/00) - B22F 10/62: by chemical means - B22F 12/53: Nozzles - B29C 64/106: using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material - B29C 64/295: Heating elements - H01F 1/12: of soft-magnetic materials - H01F 41/0206: {Manufacturing of magnetic cores by mechanical means (magnetic cores per se H01F27/24)} - B22F 3/115: by spraying molten metal, i.e. spray sintering, spray casting - B22F 10/10: Formation of a green body - B22F 10/31: Calibration of process steps or apparatus settings, e.g. before or during manufacturing - B22F 12/20: Cooling means - B22F 2009/0876: {by gas} - B22F 2009/088: {Fluid nozzles, e.g. angle, distance} - B29C 64/209: Heads; Nozzles - B33Y 10/00: Processes of additive manufacturing - B33Y 30/00: Apparatus for additive manufacturing; Details thereof or accessories therefor - C22C 2202/02: Magnetic - Y02P 10/25: Process efficiency - H01F: MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES - B05C: APPARATUS FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL (spraying apparatus, atomising apparatus, nozzles B05B; plant for applying liquids or other fluent materials to objects by electrostatic spraying B05B5/08) - B22F: WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER (making alloys by powder metallurgy C22C); APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER - B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00) - B33Y: ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - C22C: ALLOYS (treatment of alloys C21D, C22F) - Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS ## Abstract A three-dimensional magnetic printer includes at least one induction head assembly including an induction heater to heat magnetic material to form an alloy melt and at least one nozzle operable to eject the alloy melt, a coating apparatus, and a base aligned with the at least one nozzle. The induction head assembly deposits at least one alloy melt layer and the coating apparatus forms at least one insulating layer onto the base in accordance with a predetermined pattern to form a three-dimensional article. ## Claims ### Claim 1 A three-dimensional magnetic printer comprising: at least one induction head assembly including an induction heater to heat magnetic material to form an alloy melt and at least one nozzle operable to eject the alloy melt; a coating apparatus; and a base aligned with the at least one nozzle, wherein the induction head assembly deposits at least one alloy melt layer and the coating apparatus forms at least one insulating layer onto the base in accordance with a predetermined pattern to form a three-dimensional article. ### Claim 2 (depends on 1) The three-dimensional magnetic printer of claim 1, wherein the induction head assembly deposits a plurality of alloy melt layers and the coating apparatus forms at least one insulating layer between two of the plurality of alloy melt layers. ### Claim 3 (depends on 1) The three-dimensional magnetic printer of claim 1, wherein the coating apparatus comprises a sprayer. ### Claim 4 (depends on 1) The three-dimensional magnetic printer of claim 1, wherein the insulating layer is at least one of an antiferromagnetic material, a diamagnetic material, an insulating material, a non-magnetic material, a paramagnetic material, a permanent magnetic material, and a soft magnetic material. ### Claim 5 (depends on 1) The three-dimensional magnetic printer of claim 1, wherein the base has a fluid therein to cool the alloy melt. ### Claim 6 (depends on 1) The three-dimensional magnetic printer of claim 1 further comprising one or more motors operable to move at least one of the at least one induction head assembly or the base. ### Claim 7 (depends on 6) The three-dimensional magnetic printer of claim 6 further comprising a controller configured to store storing a three-dimensional model of the three-dimensional article to be printed, wherein the controller operates the motors to move the at least one induction head assembly and the base relative to each other based on the predetermined pattern, and operates the at least one nozzle to deposit the alloy melt onto the base. ### Claim 8 (depends on 1) The three-dimensional magnetic printer of claim 1 further comprising a spray device having a spout and holding a fluid made of an insulating material, and the spray device is operable to apply the fluid onto a surface of the three-dimensional article formed by the alloy melt. ### Claim 9 (depends on 1) The three-dimensional magnetic printer of claim 1 further comprising a plurality of the induction head assemblies, wherein the plurality of induction head assemblies heat different materials to be ejected by the nozzles. ### Claim 10 (depends on 1) The three-dimensional magnetic printer of claim 1 further comprising a powder forming device including a gas sprayer, wherein the powder forming device is operable to eject gas from the gas sprayer toward the alloy melt from the at least one nozzle to form a powder magnet as the three-dimensional article. ### Claim 11 (depends on 1) The three-dimensional magnetic printer of claim 1, wherein the at least one induction head assembly comprises a plurality of induction head assemblies. ### Claim 12 (depends on 11) The three-dimensional magnetic printer of claim 11, wherein the plurality of induction head assemblies heat and hold the same alloy material. ### Claim 13 (depends on 11) The three-dimensional magnetic printer of claim 11, wherein the plurality of induction head assemblies heat and hold different alloy materials. ### Claim 14 (depends on 1) The three-dimensional magnetic printer of claim 1, wherein the at least one induction head assembly comprises a plurality of nozzles. ### Claim 15 (depends on 1) The three-dimensional magnetic printer of claim 1 further comprising a 3D printer controller configured to at least one of adjust an opening defined by a nozzle control device, regulate flow of a pressurized gas into a vessel holding alloy melt, control movement of the induction head assembly, and adjust current to induction heater. ### Claim 16 A three-dimensional magnetic printer comprising: an induction head assembly including a vessel, an induction heater to heat magnetic material to form an alloy melt in the vessel and at least one nozzle with a nozzle control device operable to eject the alloy melt from the vessel; a coating apparatus comprising a sprayer; a base aligned with the at least one nozzle; and a 3D printer controller configured to at least one of adjust an opening defined by the nozzle control device, regulate flow of a pressurized gas into the vessel, control movement of the induction head assembly, and adjust current to induction heater, wherein the induction head assembly deposits at least one alloy melt layer and the coating apparatus forms at least one insulating layer onto the base in accordance with a predetermined pattern to form a three-dimensional article. ### Claim 17 (depends on 16) The three-dimensional magnetic printer of claim 16, wherein the induction head assembly deposits a plurality of alloy melt layers and the coating apparatus forms at least one insulating layer between two of the plurality of alloy melt layers. ### Claim 18 (depends on 17) The three-dimensional magnetic printer of claim 17, wherein the induction head assembly comprises a plurality of nozzles. ### Claim 19 A three-dimensional magnetic printer comprising: a plurality of induction head assemblies, wherein each of the plurality of induction head assemblies comprises a vessel and an induction heater to heat magnetic material to form an alloy melt in the vessel and at least one nozzle with a nozzle control device operable to eject the alloy melt from the vessel; a coating apparatus comprising a sprayer; and a base aligned with the at least one of the nozzles, wherein the plurality of induction head assembly deposit a plurality of alloy melt layers and the coating apparatus forms at least one insulating layer onto the base in accordance with a predetermined pattern to form a three-dimensional article. ### Claim 20 (depends on 17) The three-dimensional magnetic printer of claim 17, wherein the plurality of induction head assemblies deposit different alloy material layers onto the base.