Monolithically 3D-Printed, Miniature Solenoids with Soft Magnetic Core for Compact Systems

Abstract

We report the design, fabrication, and characterization of the first monolithically 3D-printed, three-dimensional, three-material, cored inductors for use in compact electromagnetic systems. Additive manufacturing technologies can produce functional, freeform-compatible mechanical devices; however, the ability of additive manufacturing to create electronic components that could enable the monolithic fabrication of devices that integrate sensors and actuators is still unfulfilled. This study aims at advancing the state of the art through the demonstration of the first truly three-dimensional, monolithically 3D-printed, cored solenoids. The novel 3D-printed inductors are made via material extrusion using three PLA-based materials (dielectric, conductive, and soft magnetic). The devices attain Gauss-level magnetic fields while drawing tens-of-milliamps currents. The work is of great interest for fast and inexpensive fabrication of compact sensors, actuators, and power conversion systems, and for the integration of electronics with MEMS devices of intricate geometries.