MIT engineers 3D print the electromagnets at the heart of many electronics

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"Imagine being able to build an entire dialysis machine using nothing more than a 3D printer. ...

Solenoids, electromagnets formed by a coil of wire wrapped around a magnetic core, are a fundamental building block of many electronics, from dialysis machines and respirators to washing machines and dishwashers. ...

The researchers modified a multimaterial 3D printer so it could print compact, magnetic-cored solenoids in one step. This eliminates defects that might be introduced during post-assembly processes.

This customized printer, which could utilize higher-performing materials than typical commercial printers, enabled the researchers to produce solenoids that could withstand twice as much electric current and generate a magnetic field that was three times larger than other 3D-printed devices. ..."

From the abstract:

"This study reports fully 3D-printed, three-dimensional, soft magnetic-cored solenoids that generate three times the largest magnetic fields previously reported from 3D-printed solenoids. The devices are fabricated on a customised, multi-material 3D printer that can extrude both filaments and pellets. Three different kinds of materials are employed to manufacture the reported soft magnetic-cored solenoids: pure PLA (dielectric portions), PLA doped with copper particles (electrically conductive structures), and nylon or PLA doped with metallic particles (soft magnetic cores). Via manufacturing optimisation, the reported devices are 33% smaller and can withstand about twice the current, generating three times more magnetic field. The 3D-printed solenoids generate Gauss-level magnetic fields while drawing tens-of-milliamps currents and can be readily used to implement fully 3D-printed induction sensors. The results of this work extend the state of the art in 3D-printed electronics, enabling the creation of more complex and capable solenoids for in-situ manufactured and in-space manufactured electromagnetic systems."

MIT engineers 3D print the electromagnets at the heart of many electronics | MIT News | Massachusetts Institute of Technology The printed solenoids could enable electronics that cost less and are easier to manufacture — on Earth or in space.

Three-dimensional, soft magnetic-cored solenoids via multi-material extrusion (open access)

MIT researchers modified a multi-material 3D printer so it could produce three-dimensional solenoids in one step by layering ultrathin coils of three different materials. It prints a U.S. quarter-sized solenoid as a spiral by layering material around the soft magnetic core, with thicker conductive layers separated by thin insulating layers.