This invention introduces a metal-polymer filament with up to 70% metal content for FDM 3D printing, enabling durable, precise, and customizable magnetic and metallic parts directly from desktop printers.
Magnetic component manufacturing faces challenges with traditional techniques such as air gap variability in transformer cores and geometric limitations in metal injection molding. Current high-metal-content filaments lack the strength and reliability needed for fused deposition modeling (FDM), preventing scalable desktop-level production of metallic and magnetic components. A stronger, more versatile filament solution is required to expand additive manufacturing capabilities into metal-based applications.
This invention integrates a specialized filament composed of rigid PLA and flexible TPU with up to 70% metal inclusion, compatible with standard FDM printers. The filament’s durability supports reliable 3D printing of magnetic and metallic structures. A cylindrical spiraling technique allows printing around preset windings, while real-time inductance monitoring halts printing at target values for precision control. Post-processing involves polymer removal and metal sintering, producing robust, complex geometries suitable for magnetic, heat transfer, and structural applications.
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• Precise inductance control with real-time feedback and automated stop mechanism
• High-performance filament with 65–70% metal content and superior durability
• Improved reliability during spool winding and component fabrication
• Eliminates air gaps for enhanced magnetic performance and uniformity
• Enables sintering of printed parts into complex, high-permeability structures
• Supports compact, customized designs for diverse electronic applications
• Custom electromagnetic component manufacturing
• Wireless charging coils for consumer electronics
• High-power inductors for electric vehicles
• Heat transfer components for industrial systems
• Magnetic parts for aerospace and defense technologies
• Tailored magnetic components for medical imaging devices
• US Utility Patent Application 19/177,472 – Filed April 11, 2025
Prototype – Validated at lab scale for reliable printing of high-metal-content filaments and functional inductive components. TRL ~4–5.
This technology is available for licensing.
This invention is a strong candidate for licensing by additive manufacturing companies, electronics manufacturers, and defense/aerospace suppliers seeking scalable, customizable solutions for magnetic and metallic component fabrication.
Performance data from inductance-controlled printing, filament durability testing, and post-sintering structural analysis available upon request.