Method (100) for forming a
magnet (10), wherein the method (100) comprises: Forming a
slurry (20) comprising
magnetic powder material, binder material, and a
solvent; Producing a first crude layer (14a') from the
slurry (20), wherein the first crude layer (14a') is viscous and flowable; Applying a
magnetic field (24) to the first raw layer (14a') to align the
magnetic powder material contained in the first raw layer (14a') in a desired direction; Hardening of the first raw layer (14a') to form a hardened first layer (14a) by focusing a
laser beam (28) on sections of the first raw layer (14a') that are to be part of the
magnet (10) while the
magnetic field (24) is applied to the first raw layer (14a'); after the first raw layer (14a') has hardened, a second raw layer (14b') is produced from the
slurry (20) in contact with the hardened first layer (14a), wherein the second raw layer (14b') is viscous and flowable; Applying a
magnetic field (24) to the second raw layer (14b') to align the
magnetic powder material contained in the second raw layer (14b') in the desired direction; Curing the second raw layer (14b') to form a cured second layer (14b) by focusing a
laser beam (28) on sections of the second raw layer (14a') that are to be part of the
magnet (10) while the magnetic field (24) is applied to the second raw layer (14b'), whereby the cured second layer (14b) adheres to the cured first layer (14a); wherein the generation of the slurry (20) comprises homogeneously mixing the magnetic
powder material and the binder, wherein the method (100) further comprises: Providing the magnetic
powder material comprising at least one
rare earth metal selected from
neodymium, iron and
boron, and at least one from
dysprosium and
terbium; Providing the binder, which is organic and comprises at least one of:
polyvinyl alcohol (PVA),
stearic acid,
carnauba wax, phenolic resin,
epoxy resin, nylon,
polypropylene,
polystyrene and poly(
methyl methacrylate) (PMMA); Providing the slurry (20) with a
viscosity of less than 10 Pascal-seconds;
Sintering of the cured first and second
layers (14a, 14b); and The cured first and second
layers (14a, 14b) are subjected to an isostatic
hot pressing (HIP) process.