Material extrusion with integrated compression molding of NdFeB/SmFeN nylon bonded magnets using small- and large-scale pellet-based 3D-printers
High-density bonded rare-earth magnets are manufactured using pellet-fed additive manufacturing (AM)/material extrusion and an integrated additive manufacturing-compression molding (AM-CM) process. Neodymium iron boron – samarium iron nitride in polyamide 12 (NdFeB-SmFeN/PA12) of 93 % weight fractio...
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| Format: | Article |
| Language: | English |
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Elsevier
2025-04-01
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| Series: | Additive Manufacturing Letters |
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| Online Access: | http://www.sciencedirect.com/science/article/pii/S2772369025000167 |
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| author | Kaustubh Mungale Vipin Kumar Mariappan Parans Paranthaman Brian C. Sales Harshida Parmar Ikenna C. Nlebedim Brittany Rodriguez Uday Kumar Vaidya |
| author_facet | Kaustubh Mungale Vipin Kumar Mariappan Parans Paranthaman Brian C. Sales Harshida Parmar Ikenna C. Nlebedim Brittany Rodriguez Uday Kumar Vaidya |
| author_sort | Kaustubh Mungale |
| collection | DOAJ |
| description | High-density bonded rare-earth magnets are manufactured using pellet-fed additive manufacturing (AM)/material extrusion and an integrated additive manufacturing-compression molding (AM-CM) process. Neodymium iron boron – samarium iron nitride in polyamide 12 (NdFeB-SmFeN/PA12) of 93 % weight fraction (65 % volume fraction) are used for the study. The mechanical properties (tensile strength and modulus), magnetic properties (maximum energy density, coercivity, remanence) are reported. Manufacturing parameters such as layer height, barrel temperatures, screw speed and gantry feed rate are optimized to obtain the highest possible density of the magnets using a small-scale desktop material extrusion printer. Large scale integrated additive manufacturing-compression molding (AM-CM) is then utilized to increase the density of the magnets by reducing porosity defects common in the material extrusion process. The density of as-printed magnets was 5.2 g/cm3 with a BHmax value of 124.14 kJ/m3, tensile strength of 20 MPa and a modulus of 2 GPa. AM-CM increased the density of the compound by 5.5 % (5.49 g/cm3). The reduction in porosity was confirmed using X-ray tomography (XCT). Improvement in mechanical strength of the material was also observed, with an increase in tensile strength of 25 % (25.09 MPa) and increase in tensile modulus of 275 % (5.49 GPa). Scanning electron microscopy showed increased particle-matrix adhesion with the integrated AM-CM process. |
| format | Article |
| id | doaj-art-c3d6a99d0c1144c79c3735d1e31a3e6c |
| institution | DOAJ |
| issn | 2772-3690 |
| language | English |
| publishDate | 2025-04-01 |
| publisher | Elsevier |
| record_format | Article |
| series | Additive Manufacturing Letters |
| spelling | doaj-art-c3d6a99d0c1144c79c3735d1e31a3e6c2025-08-20T03:14:49ZengElsevierAdditive Manufacturing Letters2772-36902025-04-011310028210.1016/j.addlet.2025.100282Material extrusion with integrated compression molding of NdFeB/SmFeN nylon bonded magnets using small- and large-scale pellet-based 3D-printersKaustubh Mungale0Vipin Kumar1Mariappan Parans Paranthaman2Brian C. Sales3Harshida Parmar4Ikenna C. Nlebedim5Brittany Rodriguez6Uday Kumar Vaidya7Tickle College of Engineering, The University of Tennessee, Middle Drive, Knoxville, TN 37996, USA; Manufacturing Sciences Division, Oak Ridge National Laboratory, 2350 Cherahala Blvd, Knoxville, TN 37932, USA; Institute for Advanced Composites Manufacturing Innovation, 2360 Cherahala Blvd, Knoxville, TN 37932, USA; Chemical Sciences Division, Oak Ridge National Laboratory, Oak Ridge, TN 37831, USAManufacturing Sciences Division, Oak Ridge National Laboratory, 2350 Cherahala Blvd, Knoxville, TN 37932, USAChemical Sciences Division, Oak Ridge National Laboratory, Oak Ridge, TN 37831, USA; Corresponding authors.Materials Science and Technology Division, Oak Ridge National Laboratory, Oak Ridge, TN 37831, USACritical Materials Innovation Hub, Ames National Laboratory, Ames, IA 50010, USACritical Materials Innovation Hub, Ames National Laboratory, Ames, IA 50010, USAManufacturing Sciences Division, Oak Ridge National Laboratory, 2350 Cherahala Blvd, Knoxville, TN 37932, USATickle College of Engineering, The University of Tennessee, Middle Drive, Knoxville, TN 37996, USA; Manufacturing Sciences Division, Oak Ridge National Laboratory, 2350 Cherahala Blvd, Knoxville, TN 37932, USA; Institute for Advanced Composites Manufacturing Innovation, 2360 Cherahala Blvd, Knoxville, TN 37932, USA; Corresponding authors.High-density bonded rare-earth magnets are manufactured using pellet-fed additive manufacturing (AM)/material extrusion and an integrated additive manufacturing-compression molding (AM-CM) process. Neodymium iron boron – samarium iron nitride in polyamide 12 (NdFeB-SmFeN/PA12) of 93 % weight fraction (65 % volume fraction) are used for the study. The mechanical properties (tensile strength and modulus), magnetic properties (maximum energy density, coercivity, remanence) are reported. Manufacturing parameters such as layer height, barrel temperatures, screw speed and gantry feed rate are optimized to obtain the highest possible density of the magnets using a small-scale desktop material extrusion printer. Large scale integrated additive manufacturing-compression molding (AM-CM) is then utilized to increase the density of the magnets by reducing porosity defects common in the material extrusion process. The density of as-printed magnets was 5.2 g/cm3 with a BHmax value of 124.14 kJ/m3, tensile strength of 20 MPa and a modulus of 2 GPa. AM-CM increased the density of the compound by 5.5 % (5.49 g/cm3). The reduction in porosity was confirmed using X-ray tomography (XCT). Improvement in mechanical strength of the material was also observed, with an increase in tensile strength of 25 % (25.09 MPa) and increase in tensile modulus of 275 % (5.49 GPa). Scanning electron microscopy showed increased particle-matrix adhesion with the integrated AM-CM process.http://www.sciencedirect.com/science/article/pii/S2772369025000167NdfebSmfenBonded magnetsHybrid magnetsAdditive manufacturingMaterial extrusion |
| spellingShingle | Kaustubh Mungale Vipin Kumar Mariappan Parans Paranthaman Brian C. Sales Harshida Parmar Ikenna C. Nlebedim Brittany Rodriguez Uday Kumar Vaidya Material extrusion with integrated compression molding of NdFeB/SmFeN nylon bonded magnets using small- and large-scale pellet-based 3D-printers Additive Manufacturing Letters Ndfeb Smfen Bonded magnets Hybrid magnets Additive manufacturing Material extrusion |
| title | Material extrusion with integrated compression molding of NdFeB/SmFeN nylon bonded magnets using small- and large-scale pellet-based 3D-printers |
| title_full | Material extrusion with integrated compression molding of NdFeB/SmFeN nylon bonded magnets using small- and large-scale pellet-based 3D-printers |
| title_fullStr | Material extrusion with integrated compression molding of NdFeB/SmFeN nylon bonded magnets using small- and large-scale pellet-based 3D-printers |
| title_full_unstemmed | Material extrusion with integrated compression molding of NdFeB/SmFeN nylon bonded magnets using small- and large-scale pellet-based 3D-printers |
| title_short | Material extrusion with integrated compression molding of NdFeB/SmFeN nylon bonded magnets using small- and large-scale pellet-based 3D-printers |
| title_sort | material extrusion with integrated compression molding of ndfeb smfen nylon bonded magnets using small and large scale pellet based 3d printers |
| topic | Ndfeb Smfen Bonded magnets Hybrid magnets Additive manufacturing Material extrusion |
| url | http://www.sciencedirect.com/science/article/pii/S2772369025000167 |
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