Today, almost all commercial magnet producers are using the conventional sintering magnet manufacturing procedure. Polymer bonded hard magnets has recently gain popularity as a novel magnet manufacturing technique due to its design freedom regarding shapes and magnetizing structures. Comparing to conventional magnets sintering process, the maximum energy product (BH)<sub>max</sub> of the polymer bonded magnets is lower. However, the fabrication of polymer-bonded magnets does not require high temperature sintering process and thus can be more efficient and faster process. Furthermore, no current mass production technologies can produce magnets with complex geometries up-to-date.<br/>This work utilizes paste extrusion-based direct write (DW) to fabricate UV curable polymer bonded magnets at room temperature. Direct writing (DW) is an additive manufacturing (AM) technique enabling the deposition of electronic components and functional or structural patterns using different types of materials, directly without utilizing masks or subsequent etching processes. With the removal of molding process, DW can provide intricate details and smooth surface finish. In this work, Nd-Fe-B powder are directly mixed with photo-curable binders to form a printable DW ink. Tensile tests of printed green magnet parts were conducted to understand the relationship between magnetic powder solid loading and mechanical strength. Magnetic performance of printed parts was compared to other polymer-bonded and sintered magnets. The study opens a new pathway for preparing polymer-bonded magnets at room temperature for various magnetic applications.

Direct write of UV curable polymer bonded magnets

256th National Meeting (2018)

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