High-temperature magnetic field-assisted additive manufacturing (mfaam) for creating specialized bonded magnets with tailored magnetic properties

A method for fabricating an anisotropic bonded magnet using high-temperature magnetic field-assisted additive manufacturing (MFAAM), the method comprising:

• feeding a composite filament into a 3D printer, wherein said composite filament comprises a polymer matrix and magnetic fillers;
• extruding said composite filament through a heated nozzle while applying a uniform external magnetic field via a Halbach cylinder to align said magnetic fillers in a specific direction;
• and
• actively cooling said Halbach cylinder using a fluid-filled casing to prevent heat transfer from said heated nozzle from reducing magnetic flux of said Halbach cylinder, wherein said aligned magnetic fillers are locked within said polymer matrix upon cooling to form a 3D-printed bonded magnet having a predetermined magnetic anisotropy.

A modular magnetic alignment attachment for an additive manufacturing gantry system, comprising:

• a Halbach cylinder configured to generate a magnetic field of at least 0.3 T at a print location;
• a hollow copper casing enclosing said Halbach cylinder, wherein said copper casing has fluid ports for connection to an external cooling system;
• and
• a mounting bracket configured for universal attachment to a 3D printer print head assembly.