Influence of Magnet Particle Shape on Magnetic and Environmental Stability of FDM Polymer-Bonded Magnets

In this research, the feasibility of additive manufacturing of permanent bonded magnets using fused deposition modelling (FDM) technology was investigated. The study employed polyamide 12 (PA12) as the polymer matrix and melt-spun and gas-atomized Nd–Fe–B powders as magnetic fillers. The effect of the magnetic particle shape and the filler fraction on the magnetic properties and environmental stability of polymer-bonded magnets (PBMs) was investigated. It was found that filaments for FDM made with gas-atomized magnetic particles were easier to print due to their superior flowability. As a result, the printed samples exhibited higher density and lower porosity when compared to those made with melt-spun powders. Magnets with gas-atomized powders and a filler loading of 93 wt.% showed a remanence (Br) of 426 mT, coercivity (Hci) of 721 kA/m, and energy product (BHmax) of 29 kJ/m(3), while melt-spun magnets with the same filler loading had a remanence of 456 mT, coercivity of 713 kA/m, and energy product of 35 kJ/m(3). The study further demonstrated the exceptional corrosion resistance and thermal stability of FDM-printed magnets, with less than 5% irreversible flux loss when exposed to hot water or air at 85 °C for over 1000 h. These findings highlight the potential of FDM printing for producing high-performance magnets and the versatility of this manufacturing method for various applications.