Material extrusion with integrated compression molding of NdFeB/SmFeN nylon bonded magnets using small- and large-scale pellet-based 3D-printers

Mungale, Kaustubh; Kumar, Vipin; Paranthaman, Mariappan Parans; Sales, Brian C.; Parmar, Harshida; Nlebedim, Ikenna C.; Rodriguez, Brittany; Vaidya, Uday Kumar

doi:10.1016/j.addlet.2025.100282

Material extrusion with integrated compression molding of NdFeB/SmFeN nylon bonded magnets using small- and large-scale pellet-based 3D-printers

Journal Article · Sat Apr 12 00:00:00 EDT 2025 · Additive Manufacturing Letters

DOI:https://doi.org/10.1016/j.addlet.2025.100282· OSTI ID:2573173

^[1]; ^[2]; ^[2]; ^[2]; Parmar, Harshida ^[3]; Nlebedim, Ikenna C. ^[3]; Rodriguez, Brittany ^[2]; Vaidya, Uday Kumar ^[1]

Univ. of Tennessee, Knoxville, TN (United States); Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States); Institute for Advanced Composites Manufacturing Innovation (IACMI), Knoxville, TN (United States)
Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)
Ames Laboratory (AMES), Ames, IA (United States)

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 BH_max 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.

View Accepted Manuscript (DOE)

Research Organization:: Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)

Sponsoring Organization:: USDOE Office of Energy Efficiency and Renewable Energy (EERE), Energy Efficiency Office. Advanced Materials & Manufacturing Technologies Office (AMMTO); USDOE Office of Energy Efficiency and Renewable Energy (EERE), Office of Sustainable Transportation. Vehicle Technologies Office (VTO); USDOE Office of Energy Efficiency and Renewable Energy (EERE), Renewable Power Office. Wind Energy Technologies Office

Grant/Contract Number:: AC02-07CH11358; AC05-00OR22725

OSTI ID:: 2573173

Journal Information:: Additive Manufacturing Letters, Journal Name: Additive Manufacturing Letters Vol. 13; ISSN 2772-3690

Publisher:: ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

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Related Subjects

36 MATERIALS SCIENCE
Additive manufacturing
Additive manufacturing-compression molding
Bonded magnets
Hybrid magnets
Material extrusion
Ndfeb
Polyamide 12
Smfen

Material extrusion with integrated compression molding of NdFeB/SmFeN nylon bonded magnets using small- and large-scale pellet-based 3D-printers

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References (14)

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