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Additive manufacturing and numerical modeling of injection mold for fabricating NdFeB magnets

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Abstract

This work presents the fabrication of NdFeB-based magnets using a novel method that combines powder injection and 3D printing techniques. Using customized 3D-printed plastic molds, we are able to efficiently manufacture magnets with various shapes. The injected green parts maintained near-net shape geometry. A computational model was developed to validate the design of the injection mold. The volume fraction of fluid (VOF) approach in the computational model was used to understand the flow of slurry inside the mold cavity. The computational results were promising and showed a continuous flow of slurry without any air pockets. A thorough debinding of injected green parts made sure that no binder was left behind. The microstructure and properties of the injected green parts as well as the debinded parts were investigated. The proposed method would help reduce the production cost incurred in the design and manufacturing of magnets and would also increase productivity. The magnets produced from this research could serve multiple applications in the medical, electrical, automotive and aerospace industry.

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Acknowledgments

This work was supported by the National Research Foundation of Korea (NRF) grant funded by the Korean government (MSIT) (2021R1A4A1052059), and a Korea Evaluation Institute of Industrial Technology (KEIT) grant funded by the Korean Ministry of Trade, Industry and Energy (No. 20009895), Republic of Korea.

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Authors and Affiliations

  1. Department of Mechanical and Energy Engineering, Indiana University-Purdue University Indianapolis, Indianapolis, 46202, USA

    Tejesh C Dube, Catherine Macris & Jing Zhang

  2. Department of Materials Convergence and System Engineering, Changwon National University, Changwon, 51140, Republic of Korea

    Bong-Gu Kim & Yeon-Gil Jung

Authors
  1. Tejesh C Dube
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  2. Bong-Gu Kim
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  3. Yeon-Gil Jung
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  4. Catherine Macris
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  5. Jing Zhang
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Correspondence to Jing Zhang.

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Dube, T.C., Kim, BG., Jung, YG. et al. Additive manufacturing and numerical modeling of injection mold for fabricating NdFeB magnets. Bull Mater Sci 46, 213 (2023). https://doi.org/10.1007/s12034-023-03047-6

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  • DOI: https://doi.org/10.1007/s12034-023-03047-6

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