Martin Mapley, Nicole Bartnikowski, Geoffrey Tansley, Andrew Busch and Shaun D Gregory
Griffith University, Australia
The Prince Charles Hospital, Australia
Queensland University of Technology, Australia
Monash University, Australia
Posters & Accepted Abstracts: J Material Sci Eng
The production of complex-shaped bonded NdFeB (neodymium-iron-boron) magnets is a key element in
the development of compact and efficient electromechanical devices. Due to constraints imposed by current
manufacturing methods, geometrically complex magnets are high in cost and require long lead times. The use of
additive manufacturing techniques for low volume production of complex geometries from a wide range of materials
has been shown to dramatically decrease product cost and lead times. This work describes the production and
characterisation of net-shaped bonded NdFeB magnets using selective laser sintering (SLS) from mechanically mixed
powders. Net-shaped magnets, cuboids for geometrical measurements and cylinders for magnetic measurements,
were produced using magnetic powders with both flake and spherical particle morphologies mixed with polyamide-12.
The powder loading fractions, which were based upon the ratio of the bulk density to the theoretical density of the
individual magnetic powders, were 38% and 56%/volume for the flake and spherical powders respectively. The mixed
feedstock was processed using an experimental SLS machine equipped with a mechanically tracked 15 W solid state
laser emitting radiation at a wavelength of 445 nm. The magnets were shown experimentally to possess a high level
of geometrical accuracy (less than 0.15 mm deviation from model data) with magnetic properties comparable to
permanent magnets produced using other additive manufacturing methods (residual induction of 284 and 357 mT,
intrinsic coercivity of 661 and 735 kA/m for flake and spherical powders respectively). This work has demonstrated
the feasibility of producing bonded magnets using SLS, allowing the possibility for the rapid, cost-effective production
of geometrically complex magnets.
1. T Masuzawa, M Osa and M Mapley (2017) Ô??Motor and Suspension Design,Ô?Ł Mechanical Circulatory and Respiratory Support, 1st Ed, Oxford, UK, Elsevier, ISBN: 9780128104927.
Martin Mapley is currently undertaking his PhD with Griffith University, Queensland, Australia. He is also a Researcher at the Innovative Cardiovascular Engineering and Technology Laboratory at the Prince Charles Hospital, Queensland, Australia.
E-mail: [email protected]
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