Abstract
Magnetic composites play a significant role in various electrical and electronic devices. Properties of such magnetic composites depend on the particle microstructural distribution within the polymer matrix. In this study, a methodology to manufacture magnetic composites with isotropic and anisotropic particle distribution was introduced using engineered material formulations and manufacturing methods. An in-house developed material jetting 3D printer with particle alignment capability was utilized to dispense a UV curable resin formulation to the desired computer aided design (CAD) geometry. Formulations engineered using additives enabled controlling the rheological properties and the microstructure at different manufacturing process stages. Incorporating rheological additives rendered the formulation with thixotropic properties suitable for material jetting processes. Particle alignment was accomplished using a magnetic field generated using a pair of permanent magnets. Microstructure control in printed composites was observed to depend on both the developed material formulations and the manufacturing process. The rheological behavior of filler-modified polymers was characterized using rheometry, and the formulation properties were derived using mathematical models. Experimental observations were correlated with the observed mechanical behavior changes in the polymers. It was additionally observed that higher additive content controlled particle aggregation but reduced the degree of particle alignment in polymers. Directionality analysis of optical micrographs was utilized as a tool to quantify the degree of filler orientation in printed composites. Characterization of in-plane and out-of-plane magnetic properties using a superconducting quantum interference device (SQUID) magnetometer exhibited enhanced magnetic characteristics along the direction of field structuring. Results expressed in this fundamental research serve as building blocks to construct magnetic composites through material jetting-based additive manufacturing processes.
Highlights
Material jetting is an additive manufacturing process where a three-dimensional solid part is manufactured by dispensing polymeric material from a print head and, subsequently, solidifying it utilizing an ultraviolet light or thermal curing methodology
The present study investigated the capabilities of polymer formulations engineered with magnetic fillers and additives for the material jetting additive manufacturing process
Materials developed and utilized for additive manufacturing processes are subjected to various types of shear rates and deformations during storage and/or the manufacturing process
Summary
Material jetting is an additive manufacturing process where a three-dimensional solid part is manufactured by dispensing polymeric material from a print head and, subsequently, solidifying it utilizing an ultraviolet light or thermal curing methodology. Factors that mutually influence the material process are machine andmachine materialand parameters, including liquid material influencejetting the material jetting process are material parameters, including liquidviscosity, material shear-thinning effects andeffects surface tension, headprint nozzle design, speed, droplet viscosity, shear-thinning and surfaceprint tension, head nozzleprint design, printand speed, and velocity and frequency [7]. The development of fabrication processes includes fine-tuning of material droplet velocity and frequency [7]. The development of fabrication processes includes fine-tuning of and machine in order to robust and effective additive material and parameters machine parameters inachieve order toa achieve a robust andmaterial effectivejetting-based material jetting-based manufacturing process [8,9]
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