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.
• 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
• 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.