Additive Manufacturing of Self-Magnetised Permanent Magnets
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Solution Overview
Problem
Current methods for producing permanent magnets are inefficient, requiring multiple magnetization steps and limiting production to simple geometries, leading to increased costs and magnetic orientation loss, while also prohibiting magnetized transport due to magnetic field interactions.
Innovation Solution
A method involving additive manufacturing to form a magnetizable workpiece through layer deposition and focused energy beam fusion, followed by partitioning to create a permanent magnet with complex geometries and substantial magnetic field strength without additional magnetization steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If state of the art methods use multiple magnetization steps to achieve maximum magnetic performance, then magnetic orientation is improved, but production time and cost increase
Solution Approach 1:
The patent applies preliminary action by incorporating magnetic field application during the additive manufacturing process itself, rather than as a separate post-processing step. The magnetic field is applied while the material is being deposited and solidified, allowing magnetic domains to align during formation. This eliminates the need for subsequent magnetization steps while achieving the desired magnetic performance.
Solution Approach 2:
The patent merges the manufacturing process with the magnetization process by integrating magnetic field application into the additive manufacturing sequence. The magnetic field is applied concurrently with material deposition, combining what were previously separate operations into a single unified process, thereby reducing total production time.
2Ease of manufacture
If state of the art methods use uniaxial die-pressing for shaping, then manufacturing simplicity is maintained, but geometric complexity is limited
Solution Approach 1:
The patent replaces the mechanical uniaxial die-pressing system with an additive manufacturing system that uses controlled material deposition and selective fusion. This substitution enables the creation of complex three-dimensional geometries that cannot be achieved through conventional pressing methods, while maintaining manufacturing efficiency through automated layer-by-layer construction.
Solution Approach 2:
The patent transitions from two-dimensional planar pressing to three-dimensional additive construction. By depositing material in successive layers that can be oriented in multiple directions and fused selectively, the process achieves true geometric complexity in three dimensions, overcoming the limitations of uniaxial pressing.
3Ease of operation
If magnets are transported in a magnetised state, then operational readiness is improved, but magnetic field interactions cause attraction of metal dust and other consequences
Solution Approach 1:
The patent applies preliminary action by establishing the desired magnetic field pattern during the additive manufacturing process itself. The magnetic field is applied and locked in while the material is still being formed, so the magnet achieves its final magnetic state during production rather than requiring post-manufacturing magnetization. This eliminates the need for magnetized transport while ensuring operational readiness upon completion.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces production steps, enables complex geometries, and eliminates magnetic field-related transport issues, achieving high magnetic field strength with improved efficiency and cost-effectiveness.
Implementation Method 1
forming a first workpiece layer of the magnetisable workpiece by irradiating a predetermined first area of the first powder layer by means of a focused energy beam to fuse the first powder in the first area
Implementation Method 2
Orienting the powder (i.e. the magnetic crystal anisotropy) by applying an external magnetic field
Data Source
Figure 1A~1C
Figure 1D~1E
Figure 2A~2B
AI summary
Embodiments of permanent magnets and to methods of producing permanent magnets are provided herein. Further, embodiments of electrical machines comprising permanent magnets are provided herein. The method of producing a permanent magnet 200 comprising forming a magnetisable workpiece 100 by additive manufacturing (step A)) and forming the permanent magnet 200 by partitioning the magnetisable workpiece 100, wherein an exposed surface 150 of the permanent magnet 200 formed by the partitioning is non-parallel to the first workpiece layer.