Improved Methods for 3D Printing Magnetostrictive Composites William Neave and Chase ranicke Dr. chiu law (faculty advisor) CEAS-Electrical Engineering

Introduction The goal was to improve 3D printing filament quality and magnetostrictive response from previous methods. A magnetostrictive alloy Terfenol-D was incorporated into the acrylonitrile butadiene styrene (ABS) thermoplastic matrix to enhance mechanical properties of the resulting filament. By fabricating a mixture of ABS and Terfenol-D particles, the resulting filament responds to magnetic flux by straining.

Methods 150-250 µm sized particles of Terfenol-D were mixed with particles of ABS plastic by volume fraction of 15% Terfenol-D and 85% ABS. Resulting mixture of particles was fabricated for 3D printer utilization by feeding mixture through a filament extruder (Figure 3). Constant tension was applied to end of filament to achieve a consistent diameter of resulting filament. Extrusion temperature of 185°C was used. Test blocks (Figure 5) were created with a 3D printer, then a strain gauge was added. Three blocks were printed each with a different layer orientation with respect to the applied magnetic field: 0°: along applied magnetic field 90°: orthogonal to applied magnetic field Each layer orthogonal to the previous The blocks underwent an electromagnetic test (Figure 6) to record the strain response to the magnetic flux applied. Figure 1: ABS Powder and Terfenol-D Mixture Figure 2: Filament Extruder

Figure 3 (Left): Filament Leaving Extruder Figure 4 (Right): 3D Printer Printing Testing Sample

Figure 5 (Left): Test Block with Strain Gauge Figure 6 (Right): Electromagnet

Results Figure 7: Sample Response for Orthogonally Printed Layers

Figure 8: Sample Response for Layers Printed at 0°

Figure 9: Sample Response for Layers Printed at 90°

Layers that were printed orthogonally showed largest response to the magnetic flux. Layers printed at 90° showed lowest response to magnetic flux Smaller Terfenol-D particles exhibited a lower response to magnetic flux Mixing Terfenol-D particles with ABS powder was a faster method for creating filament and printed a higher quality sample Figure 10: Results Obtained by Yermakov Running Same Test

Conclusions The current 3D printing filament composite method yielded similar results when the layers were orthogonally printed. When printed at 0°or 90° there is hysteresis that needs to be further investigated. Mechanical properties of improved method will be tested in future for comparison.

Literature Cited Engdahl, G. (2000). Handbook of Giant Magnetostrictive Materials. San Diego, CA: Academic Press Yermakov, Aleksey. “Magnetostrictive Smart Composite for Fused Deposition 3D Printing.” 28 July 2016.

Acknowledgments UW-Milwaukee Undergraduate Research Office Dr. Chiu Law Daniel Brandt Aleksey Yermakov Andrew Thompson

For Further Information Please access the Giant Handbook for Magnetostrictive Material. Additional data will be provided during the presentation.

Questions?