Additive Manufacturing Cavity for Embedded Magnet Encapsulation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for creating three-dimensional parts with localized magnetic properties using extrusion additive manufacturing face challenges such as magnet interference with the printing process and potential decay of magnetic properties due to printing temperatures, as well as complications in embedding magnets without affecting print quality or leaving cut lines and glue remnants.
Innovation Solution
A method involving forming a cavity in the three-dimensional part to house a magnet, which is then encapsulated by a cover formed from a thermally conductive polymer filament, with a system using a processor to determine the optimal gap and thickness of the cover to prevent demagnetization and interference, allowing for seamless integration of magnets during the printing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a magnet is embedded into a part using injection molding, then the part can have localized magnetic properties, but the process becomes complicated by the necessity of holding the magnet in place in the injection molding cavity during the injection molding process
Solution Approach 1:
The cavity for receiving the magnet is formed during the additive manufacturing process before the magnet is inserted. This preliminary formation of the cavity eliminates the need to hold the magnet in place during injection molding, as the magnet is inserted after the cavity is already formed and the part is removed from the molding cavity.
2Reliability
If a magnet is embedded into a part by molding with a cavity, then the part can have localized magnetic properties, but the process results in cut lines and glue remnants
Solution Approach 1:
The cover is integrated as part of the additive manufactured structure, merging the magnet housing function with the main part geometry. This integration eliminates the need for separate covering pieces that would require gluing, thereby eliminating glue remnants and improving surface quality.
3Ease of manufacture
If the extrusion barrel is formed from a magnetic material, then the printing process can be simplified, but the magnet may interfere with the extrusion process, reducing print quality or preventing completion of the print
Solution Approach 1:
The magnet is extracted from the printing process by forming the cavity and cover structure first, then inserting the magnet after the printing is complete. This separation eliminates magnetic interference with the extrusion process while allowing the use of magnetic materials for the extrusion barrel.
4Reliability
If the printing process is paused to integrate the magnet, then the magnet can be embedded in the part, but the printing time is increased and the process becomes more complex
Solution Approach 1:
The cavity and cover structure are formed in advance during the printing process before the magnet is inserted. This preliminary action allows the magnet to be integrated without pausing the printing process, as the structure is prepared beforehand and the magnet is inserted after printing is complete.
5Ease of manufacture
If high printing temperatures are used, then the polymer can be extruded effectively, but the magnetic properties of the magnets being embedded may decay
Solution Approach 1:
The magnet is extracted from the thermal environment by inserting it after the printing process is complete. This timing separation allows the polymer to be extruded at high temperatures without exposing the magnet to those temperatures, thereby preserving the magnet's magnetic properties.
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 enables the creation of parts with embedded magnets of various sizes and strengths without affecting print quality, eliminates the need for holding the magnet in place, and reduces post-processing requirements, resulting in improved part quality and magnetic property retention.
Implementation Method 1
The barrel is often heated to reduce the viscosity of the polymer filament, allowing the polymer filament to flow sufficiently for deposition onto the support bed.
Implementation Method 2
a magnet may be embedded into the part using various processes
Data Source
AI summary
A three-dimensional part as well as a method and system for creating the three-dimensional part. The three-dimensional part including a first portion of a three-dimensional part formed from a first plurality of successively deposited layers, with a cavity defined in the first portion of the three-dimensional part. A magnet is inserted in the cavity and a cover disposed on the magnet in the cavity. In addition, a second portion of the three-dimensional part is formed form a second plurality of successively deposited layers deposited on the first portion of the three-dimensional part and the cover.