Nested Halbach Magnetic Field Control for Composite 3D Printing
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Solution Overview
Problem
Existing 3D printing technologies face challenges in generating a homogeneous magnetic field that is easily adjustable in intensity and spatial direction, limiting the precise control of magneto-responsive fillers during the printing process.
Innovation Solution
A magnetic device comprising nested Halbach cylinder arrays and a solenoid, allowing for the generation of a homogeneous magnetic field with adjustable intensity and spatial direction, compatible with various additive manufacturing machines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If single permanent magnets are used to generate magnetic field, then device complexity is reduced and compactness is improved, but magnetic field homogeneity deteriorates due to field gradient
Solution Approach 1:
The magnetic device is segmented into multiple permanent magnets arranged in a specific configuration (e.g., Halbach array or opposing pairs) to cancel out field gradients and achieve homogeneity while maintaining structural simplicity
Solution Approach 2:
Asymmetric arrangement of permanent magnets with varying strengths or orientations is used to compensate for natural field gradients, creating a homogeneous region through deliberate asymmetric design rather than symmetric cancellation
2Manufacturing precision
If multiple permanent magnets or electromagnets are used to improve magnetic field homogeneity, then magnetic field homogeneity is improved, but device complexity and setup space increase
Solution Approach 1:
Multiple magnets are nested or layered in compact configurations where inner magnets are surrounded by outer magnets, achieving field homogeneity through layered arrangement while minimizing overall device footprint and complexity
Solution Approach 2:
The magnetic device design integrates multiple functions into a single configuration, where the same magnet arrangement serves both to generate homogeneous field and to maintain compactness, eliminating the need for separate adjustment mechanisms
3Manufacturing precision
If Helmholtz coils are used to generate homogeneous magnetic field, then magnetic field homogeneity is improved, but device complexity and layout space increase
Solution Approach 1:
Electromagnetic coils (Helmholtz configuration) are replaced with permanently magnetized materials arranged in specific geometric patterns, eliminating the need for power-consuming coils while maintaining field homogeneity through magnetic material geometry
4Manufacturing precision
If distributed electromagnets with positioning adjustment are used, then magnetic field homogeneity and directional control are improved, but device complexity and layout restrictions increase
Solution Approach 1:
The magnetic device incorporates movable or adjustable components that allow dynamic reconfiguration of magnet positions or orientations, enabling spatial field control without requiring complex distributed electromagnet systems with multiple adjustment mechanisms
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
Enables the precise orientation and alignment of magneto-responsive fillers, resulting in composite materials with tailored magnetic and reinforced properties, improving the precision and versatility of 3D printing processes.
Implementation Method 1
an inner and an outer nested concentric Halbach cylinder arrays sharing a common revolution axis oriented along the Z-axis, each of said inner and outer Halbach cylinder arrays generating a homogeneous magnetic field
Implementation Method 2
a solenoid (113) positioned within a core of the inner Halbach cylinder array (111), and having a revolution axis aligned with the common revolution axis of the inner and outer Halbach cylinder arrays, the solenoid generating and adjusting a magnetic field Bz
Implementation Method 3
The application of a magnetic field allows to orient and align the magneto-responsive fillers
Data Source
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AI summary
The invention relates to a magnetic device (11) configured to generate a homogeneous magnetic field B in a specific zone (115), the magnetic field B having spatial components Bx, By and Bz along X, Y and Z axes of a Cartesian reference frame, said magnetic field 13 being adjustable in intensity ∥B∥ and three-dimensional spatial direction, the magnetic device (11) to be installed on additive manufacturing apparatuses enabling a magnetically-assisted 3D printing of composite elements, the magnetic device (11) comprising: ∘ an inner (111) and an outer (112) nested concentric Halbach cylinder arrays sharing a common revolution axis oriented along the Z-axis, each inner (111) and outer (112) Halbach cylinder arrays generating a homogeneous magnetic field of equal intensity B0, the inner (111) and outer (112) Halbach cylinder arrays allow generating a resulting magnetic field Bx,y (α, β) in the XY-plane, with spatial components Bx and By, the inner (111) and outer (112) Halbach cylinder arrays being mounted to rotate around their common revolution axis in order to achieve adjustability of both intensity and spatial direction of the resulting magnetic field Bx,y (α, β) in the XY-plane; ∘ a solenoid (113) positioned within a core of the inner Halbach cylinder array (111), and having a revolution axis aligned with the common revolution axis of the inner (111) and outer (112) Halbach cylinder arrays, the solenoid (113) generating and adjusting a magnetic field Bz of spatial component Bz along the Z-axis, the specific zone (115) being located in a core of the solenoid (113).