Rheology-Assisted Microstructure Control for Printing Magnetic Composites-Material and Process Development

Magnetic 3D-Printed Composites-Production and Applications

Three-dimensional printing enables building objects shaped with a large degree of freedom. Additional functionalities can be included by modifying the printing material, e.g., by embedding nanoparticles in the molten polymer feedstock, the resin, or the solution used for printing, respectively. Such composite materials may be stronger or more flexible, conductive, magnetic, etc. Here, we give an overview of magnetic composites, 3D-printed by different techniques, and their potential applications. The production of the feedstock is described as well as the influence of printing parameters on the magnetic and mechanical properties of such polymer/magnetic composites.

Development and Characterization of Field Structured Magnetic Composites

Polymer composites containing ferromagnetic fillers are promising for applications relating to electrical and electronic devices. In this research, the authors modified an ultraviolet light (UV) curable prepolymer to additionally cure upon heating and validated a permanent magnet-based particle alignment system toward fabricating anisotropic magnetic composites. The developed dual-cure acrylate-based resin, reinforced with ferromagnetic fillers, was first tested for its ability to polymerize through UV and heat. Then, the magnetic alignment setup was used to orient magnetic particles in the dual-cure acrylate-based resin and a heat curable epoxy resin system in a polymer casting approach. The alignment setup was subsequently integrated with a material jetting 3D printer, and the dual-cure resin was dispensed and cured in-situ using UV, followed by thermal post-curing. The resulting magnetic composites were tested for their filler loading, microstructural morphology, alignment of the easy axis of magnetization, and degree of monomer conversion. Magnetic characterization was conducted using a vibrating sample magnetometer along the in-plane and out-of-plane directions to study anisotropic properties. This research establishes a methodology to combine magnetic field induced particle alignment along with a dual-cure resin to create anisotropic magnetic composites through polymer casting and additive manufacturing.

Process-Structure-Properties in Polymer Additive Manufacturing

Additive manufacturing (AM) methods have grown and evolved rapidly in recent years [...].