The researchers were able to produce a variety of differently shaped magnets with a 3D printer. Photo by TU Wien

VIENNA, Oct. 25 (UPI) -- From a technological perspective, making a powerful magnet is no problem. Precisely controlling the shape of magnet's magnetic field, however, has proven difficult -- until now.

Engineers at TU Wien have for the first time designed and produced magnets using a 3D printer.


The method offers scientists newfound control over the size and shape of the magnetic field, allowing them to produce magnets that better meet the needs of a range of technologies.

"The strength of a magnetic field is not the only factor," Dieter Süss, material scientist at TU Wien, said in a news release. "We often require special magnetic fields, with field lines arranged in a very specific way -- such as a magnetic field that is relatively constant in one direction, but which varies in strength in another direction."

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Scientists have had the know-how to design the ideal structural patterns for specific magnetic circumstances, but that knowledge has been mostly relegated to the computer. Traditional injection-mold technology is too expensive and time consuming to make the translation of the digital science worthwhile.

That's not the case with 3D printers, which are fast, cost-effective and ideal for small-batch production.

The 3D printer uses magnetic micro granulate to create intricately designed geometric patterns. The granulate structures are bound together by a special polymer. The printed product isn't actually magnetic fresh out of the machine. The granulate is printed in an unmagnetized state. But when the printed object is exposed to a strong magnetic field, the granulate takes on its intended magnetism.

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"This method allows us to process various magnetic materials, such as the exceptionally strong neodymium iron boron magnets," explained Süss. "Magnet designs created using a computer can now be quickly and precisely implemented -- at a size ranging from just a few centimeters through to decimeters, with an accuracy of well under a single millimeter."

Researchers say their findings -- detailed in the journal Applied Physics Letters -- will not only improve current technologies, but empower new ones.

"Now we will test the limits of how far we can go -- but for now it is certain that 3D printing brings something to magnet design which we could previously only dream of," Süss concluded.

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