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Net Shape 3D Printed NdFeB Permanent Magnet

For two decades, NdFeB based magnets have been a critical component in a range of electrical devices engaged in energy production and conversion. The magnet shape and the internal microstructure of the selected NdFeB grade govern their efficiency and size. However, stricter requirements on device efficiency call for better performing magnets preferably with novel functionality not achievable today. Here we use 3D metal printing by Selective Laser Melting to fabricate dense net shape permanent magnets based on NdFeB that exhibit high magnetic performance. Evidence is provided that the internal microstructure, not achievable by traditional manufacturing means, is the origin of the solid magnetic properties. The freedom in magnet body shape and size that ranges from the millimeter to tens of centimeter scale opens up a design freedom that could be a catalyzer for the next generation of electrical devices.