US 11,721,458 B2
Methods for tailoring magnetism, and structures obtained therefrom
Brennan Yahata, Santa Barbara, CA (US); Eric Clough, Santa Monica, CA (US); Christopher Henry, Thousand Oaks, CA (US); Amber Sucich, Calabasas, CA (US); Darby Laplant, Santa Monica, CA (US); and Tobias Schaedler, Oak Park, CA (US)
Assigned to HRL Laboratories, LLC, Malibu, CA (US)
Filed by HRL Laboratories, LLC, Malibu, CA (US)
Filed on Jun. 26, 2021, as Appl. No. 17/359,557.
Claims priority of provisional application 63/061,800, filed on Aug. 6, 2020.
Claims priority of provisional application 63/061,798, filed on Aug. 6, 2020.
Prior Publication US 2022/0044870 A1, Feb. 10, 2022
Int. Cl. H01F 41/02 (2006.01); H01F 13/00 (2006.01); H01F 7/02 (2006.01); H01F 1/057 (2006.01); H01F 1/055 (2006.01); C22C 38/00 (2006.01); C22C 38/30 (2006.01); C22C 38/08 (2006.01); C22C 38/10 (2006.01); C22C 38/06 (2006.01); B33Y 80/00 (2015.01)
CPC H01F 1/055 (2013.01) [B33Y 80/00 (2014.12); C22C 38/005 (2013.01); C22C 38/06 (2013.01); C22C 38/08 (2013.01); C22C 38/105 (2013.01); C22C 38/30 (2013.01); H01F 1/0577 (2013.01); H01F 7/021 (2013.01); H01F 7/0278 (2013.01); H01F 13/003 (2013.01); H01F 41/0266 (2013.01); H01F 41/0273 (2013.01); C22C 2202/02 (2013.01)] 22 Claims
OG exemplary drawing
 
1. A method of making a magnet with tailored magnetism by additive manufacturing, said method comprising:
(a) providing a feedstock composition containing base particles and one or more surface-modifying particles that are chemically and/or physically disposed on surfaces of said base particles, wherein said surface-modifying particles are magnetic or magnetically susceptible;
(b) exposing a first amount of said feedstock composition to an energy source for melting in a scan direction, thereby generating a first melt layer;
(c) solidifying said first melt layer in presence of an externally applied magnetic field, thereby generating a magnetic metal layer containing a plurality of individual voxels;
(d) optionally repeating steps (b) and (c) a plurality of times to generate a plurality of solid layers by sequentially solidifying a plurality of melt layers in a build direction, thereby generating a plurality of magnetic metal layers; and
(e) recovering a magnet comprising said magnetic metal layer,
wherein said externally applied magnetic field has a magnetic-field orientation, defined with respect to said scan direction, that is selected to control a magnetic axis within said magnetic metal layer.