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.
Background: 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.
Technology Overview: 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.
Advantages: • 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
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
Intellectual Property Summary: • US Utility Patent Application 19/177,472 – Filed April 11, 2025
Stage of Development: Prototype – Validated at lab scale for reliable printing of high-metal-content filaments and functional inductive components. TRL ~4–5.
Licensing Status: This technology is available for licensing.
Licensing Potential: 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.
Additional Information: Performance data from inductance-controlled printing, filament durability testing, and post-sintering structural analysis available upon request.
Inventors: Oscar Abundez, Pritam Das, Jacob Goodman, Scott Schiffres