DUBOIS, PA – Magnet Applications®, Inc., the only North American manufacturer of compression bonded magnets and a leading manufacturer of injection molded magnets, hybrid magnets and magnetic assemblies, today announced a breakthrough in 3D printed neodymium iron boron (NdFeB) magnets. Engineers from Magnet Applications, working together with researchers at Oak Ridge National Laboratory, have proven that permanent magnets produced by additive manufacturing (commonly referred to a “3D Printing”) outperform bonded magnets using traditional methods with less waste.
Magnet Applications, Inc., a Bunting® Magnetics Company, manufactured the starting composite pellets with 65 volume percent isotropic NdFeB powder and 35 percent polyamide nylon-12 binder in a precise ratio, blended to a consistent texture. The 3D printing was performed at the Manufacturing Demonstration Facility at Oak Ridge National Laboratory with the Big Area Additive Manufacturing (BAAM system). Oak Ridge National Laboratory is a Tennessee-based science and technology laboratory managed by the United States Department of Energy. The complete study is published in Scientific Reports..
“Additive manufacturing in magnets provides multiple benefits,” commented Dr. John Ormerod, Senior Technical Advisor, Magnet Application, Inc. “They have more design flexibility, which is especially beneficial in sensor technology and it creates less waste than in the traditional sintering process.”
NdFeB magnets are the most powerful on earth, and used in everything from robotics, wind turbines, electric vehicles, cell phones, electric motors and other consumer and industrial equipment.
“With rapidly advancing technologies, the ability to manufacture the strongest magnet available in any shape without tooling, in any quantity, unleashes so many design opportunities. The work has demonstrated the potential of additive manufacturing to be applied to wide range of magnetic materials and assemblies,” Ormerod continued.
“Magnet Applications and many of our customers are excited to explore the commercial impact of this technology in the future,” he added.
With control over the size and shape of the magnet – as well as the magnetic field – further research will include printing magnets in various strengths with preferred direction of magnetization.
Contributing to the project were Ling Li, Angelica Tirado, Orlando Rios, Brian Post, Vlastimil Kunc, R. R. Lowden, Edgar Lara-Curzio at ORNL, as well as researchers I. C. Nlebedim and Thomas Lograsso working with CMI at Ames Laboratory. Robert Fredette and John Ormerod from Magnet Applications Inc. (MAI) contributed to the project through an MDF technology collaboration. The DOE’s Advanced Manufacturing Office provides support for ORNL’s Manufacturing Demonstration Facility, a public-private partnership to engage industry with national labs.
The article is available to view on the Nature website at: http://www.nature.com/articles/srep36212.
About Magnet Applications®, A Bunting® Magnetics Company
Magnet Applications, Inc., is part of Bunting® Magnetics Co. family of companies, a global provider of magnets and magnetic separation, metal detection and material handling equipment as well as a complete line of magnetic printing cylinders. Magnet Applications is the only North American manufacturer of compression bonded magnets, injection molded magnets, hybrid magnets and magnetic assemblies for the worldwide Automotive & Transportation, Industrial & Commercial, Medical Equipment, Military & Aerospace, Security and other industries. Its products are primarily used in PM motors and magnetic sensors. Magnet Applications, Inc. facilities are located in Dubois, Pennsylvania with sales support worldwide. The company is ITAR/DFARS and ISO 9001:2008 registered. For additional information, call 1-800-437-8890 or 1-814-375-9145 or visit magnetapplications.com. Follow Magnet Applications on Twitter @MagApplications and LinkedIn.
About Bunting® Magnetics Co.
Since the company’s 1959 founding, Bunting® Magnetics has led the industry in both durability and performance in its line metal detection, magnetic separation and material handling equipment as well as printing cylinders for several global markets: Recycling, food packaging and processing, feed and grain, plastics, pharmaceuticals, chemicals, offset printing, metal stamping, automobile manufacturing and more. Bunting magnets are also available at buymagnets.com. Bunting Magnetics facilities are located in Newton, Kansas; suburban Chicago, Illinois; DuBois, Pennsylvania; and Berkhamsted, England. For additional information, call 1-800-835-2526 or +44 (0) 1442 875081 or visit buntingmagnetics.com or buntingeurope.com. Follow Bunting on Twitter (@BuntingMagCo) and LinkedIn (Bunting Magnetics Co).