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DOE OSTI2024

Robust Solar Receivers Using MAX Phase Materials

This work was supported by the U.S. Department of Energy’s Office of Energy Efficiency and Renewable Energy under the Solar Energy Technologies Office Award Number 35928. The objective of the proposed effort was to develop and optimize additive manufacturing technologies for low-cost fabrication of high-temperature receivers using MAX phase-based materials (Ti 3 SiC 2 and Ti 3 AlC 2 ). MAX phase materials are a group of ternary metal carbides and nitrides where M stands for an early transition metal element, A is a group 13–16 element, and X is C and/or N. In Phase 1, the binder jetting additive manufacturing process was used to synthesize and characterize the Ti 3 SiC 2 MAX phase material. The typical process involved first producing a TiC preform using binder jetting followed by infiltration of the preform with silicon melt to form Ti 3 SiC 2 in situ. The reaction-infiltrated samples showed formation of MAX phase in the sample core; however, the surface showed cracking. Various process conditions—cooling rates, hold times, Si proportion, etc.—were varied to minimize the surface cracking. The fabricated MAX phase core was characterized by microstructure analysis and evaluations of mechanical properties such as hardness and thermal shock. In Phase 2, the focus included fabrication of Ti 3 SiC 2 MAX phase materials by spark plasma sintering (SPS) and synthesis of Ti 3 AlC 2 MAX phase materials by the Al melt infiltration process. It is expected that Al infiltration will not cause sample cracking, since Al does not expand during solidification. In addition, other processing approaches were investigated to fabricate the MAX phase materials, such as SPS with a graphite bedding approach for producing short-length Ti 3 AlC 2 MAX phase tubes for demonstration of prototypical Concentrating Solar Power receiver tubes. Fabricated samples underwent thermo-mechanical testing to validate the materials for the solar receiver application at temperatures >1000°C. In Phase 3, the effort focused on the development and optimization of the Ti-Al-C MAX phase composite material using the Al melt infiltration approach. We started with optimization of precursor powders and making preform structures by either pressing them in a die or using the binder jetting additive manufacturing process followed by Al melt infiltration. In addition, we investigated the formation of preform structures by cold isostatic pressing followed by Al melt infiltration for making Ti-Al-C MAX phase composite. Thermo-mechanical characterizations, such as creep, strength, and thermal shock, were conducted to establish the structures’ performance.

36 MATERIALS SCIENCE↗

DOE OSTI2026

Direct Processing of Lithium Chloride Based Waste Salt in a Ceramic Waste Form

Ceramic waste form materials were fabricated with a LiCl based salt mixture to demonstrate the suitability of direct processing of waste salt from an all LiCl pyroprocessing flow sheet on the formation, microstructure, and durability of ceramic waste forms. Materials were successfully synthesized by using the simplified direct processing technique with salt loadings of 5, 7.5, and 10 wt% at the laboratory scale. Materials fabricated with LiCl based salt indicated full conversion of zeolite to sodalite occurred to form products with low open porosity. This indicates that the Na 2 O content of NBS4 glass is suitable for processing salt chemistries which do not contain NaCl. Generated sodalite was microencapsulated by the glass binder, halite occlusions were detected within sodalite domains at all salt loadings, and a Cs-rich phase believed to be Cs-pollucite was detected in the material made with the lowest salt loading (5 wt%). Salt inclusions were encapsulated within the binder glass at all loadings, and found to consist primarily of NaCl with Cs present. A small amount of salt was found at the surface of the wasteform made with the highest salt loading of 10 wt%, which may indicate an upper limit to the amount of salt that can be accommodated or incomplete mechanical mixing of the reagents. Durability testing by using the ASTM C1308 method indicated that initial rapid dissolution of exposed halite inclusion phases was directly correlated to salt loading. Wasteform degradation during all tests occurred primarily due to dissolution of the sodalite phase. Durability of the binder glass was found to increase as the waste salt loading increased. Results for the release of cations from the salt indicate the changes in wasteform durability and halite inclusion chemistry are strongly influenced by ion exchange phenomena between the salt and the glass. This appears to be the result of the relatively stronger affinity for the glass phase of Li, compared to that of other cations such as Na and Cs. The effects from cation exchange were diminished at lower salt loadings.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2023

Electrospun Si and Si/C Fiber Anodes for Li-Ion Batteries

Due to structural changes in silicon during lithiation/delithiation, most Li-ion battery anodes containing silicon show rapid gravimetric capacity fade upon charge/discharge cycling. Herein, we report on a new Si powder anode in the form of electrospun fibers with only poly(acrylic acid) (PAA) binder and no electrically conductive carbon. The performance of this anode was contrasted to a fiber mat composed of Si powder, PAA binder, and a small amount of carbon powder. Fiber mat electrodes were evaluated in half-cells with a Li metal counter/reference electrode. Without the addition of conductive carbon, a stable capacity of about 1500 mAh/g (normalized to the total weight of the anode) was obtained at 1C for 50 charge/discharge cycles when the areal loading of silicon was 0.30 mgSi/cm2, whereas a capacity of 800 mAh/g was obtained when the Si loading was increased to ~1.0 mgSi/cm2. On a Si weight basis, these capacities correspond to >3500 mAh/gSi. The capacities were significantly higher than those found with a slurry-cast powdered Si anode with PAA binder. There was no change in fiber anode performance (gravimetric capacity and constant capacity with cycling) when a small amount of electrically conductive carbon was added to the electrospun fiber anodes when the Si loading was ≤1.0 mgSi/cm2.

Mondal, Abhishek N.↗

DOE OSTI2022

Targeting a Conserved Lysine in the Hydrophobic Pocket of HIV-1 gp41 Improves Small Molecule Antiviral Activity

Human Immunodeficiency virus (HIV-1) fusion is mediated by glycoprotein-41, a protein that has not been widely exploited as a drug target. Small molecules directed at the gp41 ectodomain have proved to be poorly drug-like, having moderate efficacy, high hydrophobicity and/or high molecular weight. We recently investigated conversion of a fairly potent hydrophobic inhibitor into a covalent binder, by modifying it to react with a lysine residue on the protein. We demonstrated a 10-fold improvement in antiviral efficacy. Here, we continue this study, utilizing instead molecules with better inherent drug-like properties. Molecules possessing low to no antiviral activity as equilibrium binders were converted into µM inhibitors upon addition of an electrophilic warhead in the form of a sulfotetrafluorophenyl (STP) activated ester. We confirmed specificity for gp41 and for entry. The small size of the inhibitors described here offers an opportunity to expand their reach into neighboring pockets while retaining drug-likeness. STP esterification of equilibrium binders is a promising avenue to explore for inhibiting HIV-1 entry. Many gp41 targeting molecules studied over the years possess carboxylic acid groups which can be easily converted into the corresponding STP ester. It may be worth the effort to evaluate a library of such inhibitors as a way forward to small molecule inhibition of fusion of HIV and possibly other enveloped viruses.

60 APPLIED LIFE SCIENCES↗

DOE OSTI2020

Protective aluminum oxide surface coatings and low-temperature forming process for high-temperature applications

A method of both coating a substrate with aluminum oxide and infusing the substrate with elemental aluminum is disclosed. In one example, the method includes providing a metal powder/polymer binder slurry, the slurry having a solvent, an organic binder, metal granules and a seed element, wherein the metal granules include Al; dispersing the slurry upon a Cr-containing surface; after dispersing the slurry, exposing the slurry to air and maintaining the temperature of the slurry and substrate below 110° C. to remove at least a portion of the solvent from the slurry; and, in a combined step, both exposing the binder, metal granules and substrate to air and heating the remaining slurry and substrate at a temperature less than or equal to 1000° C. to both diffuse at least a portion of the metal of the metal granules into the substrate and coat the substrate with aluminum oxide.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Binderjet Additive Manufacturing for Complex Heat Exchanger Geometries

Concentrated Solar Power (CSP) systems play a role in the worlds development of renewable energy. Mirrors are used to concentrate sunlight that is converted into electricity or other forms of useful energy. CSP impact depends significantly on its overall economics. The U.S. Department of Energy’s (DOE’s) Solar Energy Technology Office (SETO) cost goals for 2030include $0.05/kWh levelized cost of electricity (LCOE) for a baseload plant [1]. The power cycle cost goal is $900/kWe [1]. The envisioned recompression supercritical carbondioxide (sCO2) power cycle includes four heat exchangers, which together are at least ¾ of the total power cycle cost. Meeting the cost target requires reducing the heat exchanger cost. The 260 bar and 588 °C heat exchanger requirements are challenging. Shell and tube heat exchangers can meet the requirements, but the size and cost are prohibitive. State-of-the-art diffusion bonded printed circuit heat exchanger designs are 3 m3 or larger and expensive to manufacture. Additive manufacturing enables novel heat exchanger geometries that can reduce heat exchanger size and mass [2]. Binderjet technology is an additive manufacturing modality. It selectively deposits binder material onto the powder bed to form a solid part one layer at a time. Once applied, the binder is cured, the remaining powder removed, and the part heat treated in steps to remove the binder, sinter the metal powder, and densify the part. The Binderjet printing process is more than 10x faster than the best-known metal additive modality, direct metal laser melting (DMLM), thus enabling 10x the part through-put rate [3]. The high throughput rate results in a low-cost manufacturing process capable of creating complex heat exchanger geometries. This paper introduces a complex heat exchanger geometry and methods of Binderjet processing to fabricate the geometry.

Barua, Ananda↗

DOE OSTI2023

Indirect additive manufacturing process

A method for indirect additive manufacturing of an object, the method comprising: (i) separately feeding a powder from which said object is to be manufactured and either a difunctional curable monomer according to Formula (I) or an adhesive polymer binder into an additive manufacturing device; (ii) dispensing selectively positioned droplets of said difunctional curable monomer or adhesive polymer binder, from a printhead of said additive manufacturing device, into a bed of said powder to bind particles of said powder with said difunctional curable monomer or adhesive polymer binder to produce a curable preform having a shape of the object to be manufactured; and, in the case of the difunctional curable monomer, (iii) curing said curable preform to form a crosslinked object.

Saito, Tomonori↗

DOE OSTI2023

Functionalized Silicon Particles for Enhanced Half- and Full-Cell Cycling of Si-Based Li-Ion Batteries

Vinylene carbonate (VC) and polyethylene oxide (PEO) have been investigated as functional agents that mimic the solid electrolyte interphase (SEI) chemistry of silicon (Si). VC and PEO are known to contribute to the stability of Si-based lithium-ion batteries as an electrolyte additive and as a SEI component, respectively. In this work, covalent surface functionalization was achieved via a facile route, which involves ball-milling the Si particles with sacrificial VC and PEO. Thermogravimetric analysis (TGA), X-ray photoelectron spectroscopy (XPS), and magic angle spinning nuclear magnetic resonance (MAS NMR) spectroscopy indicate that the additives are strongly bound to Si. In particular, MAS NMR shows Si–R or Si–O–R groups, which confirm functionalization of the Si after milling in VC or PEO. Particle size analysis by dynamic light scattering reveals that the additives facilitate particle size reduction and that the functionalized particles result in more stable dispersions based on zeta potential measurements. Raman mapping of the electrodes fabricated from the VC and PEO-coated active material with a polyacrylic acid (PAA) binder reveals a more homogenous distribution of Si and the carbon conductive additive compared to the electrodes prepared from the neat Si. Furthermore, the VC-milled Si strikingly exhibited the highest capacity in both half- and full-cell configurations, with more than 200 mAh g –1 measured capacity compared to the neat Si in the half-cell format. This is linked to an improved electrode processing based on the Raman and zeta potential measurements as well as a thinner SEI (with more organic components for the functionalized Si relative to the neat Si) based on XPS analysis of the cycled electrodes. In conclusion, the effect of binder was also investigated by comparing PAA with P84 (polyimide type), where an increased capacity is observed in the latter case.

25 ENERGY STORAGE↗

DOE OSTI2025

Compatibilization Strategy and Mechanism for Co-stabilizing Commingled Plastics and Pyrolyzed Rubber in Asphalt

Hot mix asphalt mixture is considered the ideal approach to reuse waste plastics in high-value applications because of its very high amount of usage in highway construction. However, the differences in polarity and density between polymers and asphalt lead to polymer coalescence and therefore the poor storage stability of modified asphalt. These challenges are exalted when recycling commingled plastics. This study introduced an innovative compatibilization strategy and mechanism for co-stabilizing commingled plastics and pyrolyzed rubber in asphalt. Commingled plastics were first grafted with maleic anhydride for surface activation, followed by reactive kneading with pyrolyzed rubber and crosslinking agent to form an integrated thermoplastic elastomer (ITPE) for asphalt modification. The mechanical, thermal, and interfacial behaviors of the ITPE were evaluated through tensile testing, thermogravimetric analysis, and scanning electron microscopy. The storage stability and rheological properties of the modified binder blends were evaluated through the cigar tube test and dynamic shear rheometer testing. Results demonstrated a successful formation of imide bonds in the ITPE, which can improve the strength, ductility, and thermal stability of rubber–plastic composites. Appropriate utilization of crosslinking agents can improve both rutting and fatigue resistance of ITPE-modified asphalt with good storage stability because of the co-existence of rigid plastic and soft rubbery regimes and the formation of a crosslink network. Furthermore, excessive content of crosslinker led to severe phase separation and reduced storage stability of modified binder blends. Extra crosslinker tended to float in asphalt because of its low density and caused an excessive formation of the crosslink network in the top section of the asphalt.

asphalt binder modifiers↗

DOE OSTI2024

Mechanical and Electrochemical Implications of Drying Temperature on Lithium‐Ion Battery Electrodes

Abstract Lithium‐ion battery (LIB) electrodes are typically produced with n‐methyl‐2‐pyrrolidone, a toxic solvent that is a known carcinogen and reproductive hazard. Accordingly, aqueous processing has been an expanding area of research interest in the field of LIB manufacturing. Although aqueous processing has been widely successful in anode processing, serious challenges remain in processing the cathode. In this work, the drying mechanics of cathode processed with both solvents is investigated though implementation of a chemical‐engineering‐based model to better understand the utilization of heat provided by experimentally determining the heat and mass transfer coefficients. Electrochemical performance is also evaluated to determine the impact of drying temperature on cycling performance. Binder distribution is determined via various methods to confirm differences in binder homogeneity as a function of both solvent and drying temperature. Identified is the large difference in the efficiency in which the heat is used as well as an ideal drying temperature for both aqueous and non‐aqueous processed cathodes. Also identified is the increased sensitivity to processing temperature for aqueous processed electrodes compared to non‐aqueous processed counterparts, pointing to the possibility of tuned drying regimes which would capitalize on the potential cost savings of aqueous processing for cathodes.

25 ENERGY STORAGE↗

DOE OSTI2021

Phase segregation mechanisms of small molecule-polymer blends unraveled by varying polymer chain architecture

As phase separation between the small-molecule semiconductor and the polymer binder is the key enabler of blend-based organic field-effect transistors (OFETs) fabricated by low-cost solution processing, it is crucial to understand the underlying phase separation mechanisms that determine the phase morphology, which significantly impacts device performance. Beyond the parameter space investigated in previous work, here we investigate the formation of blends by varying the branch architecture of the polymer binder and by shortening the solvent dry time using ultrasonic spray casting. The phase morphologies of the resulting blend films have been thoroughly characterized with a variety of techniques in three dimensions over multiple length scales, including AFM, energy-filtered transmission electron microscope, and neutron reflectivity, and have been correlated with electrical transport performance. From the results, we have inferred that the phase morphology is kinetically determined, limited by the inherent slow movement of polymer macromolecules. The kinetic picture, supported by molecular dynamics modeling, not only consistently explains our observations but also resolves inconsistencies in previous works. The achieved mechanistic understanding will guide further optimization of blend-based organic electronics, such as OFETs and organic photovoltaics.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Strategies for Developing High-Volume Fly Ash Concrete with High Early-Age Strength for Precast Applications

Partial replacement of portland cement with supplementary cementitious materials (SCMs), such as fly ash, is an effective strategy for improving durability and reducing the CO 2 footprint of concrete. However, using high-volume fly ash (HVFA) binders in precast and prestressed concrete is currently limited; largely due to reduced early-age strength development that impedes rapid production and prestressing of precast concrete. To investigate and address this challenge, HVFA mortars with a minimum of 40% fly ash by mass of cementitious materials were developed and tested in this study. Two fresh fly ashes (an ASTM C618 Class F and a Class C) and a landfilled fly ash (Class F) were included. Various strategies for improving the early strength were evaluated, including gypsum optimization, chemical accelerators, steam curing, use of CSA cements, and adding other reactive SCMs like silica fume, calcined clay, and slag cement. Steam curing and the use of CSA cement at high dosages (40% of total binder) were found to be the most successful strategies across all three fly ashes. Additionally, significant improvements were observed with gypsum optimization (for Class C fly ash) and the use of accelerators (for Class F fly ashes), and these strategies are likely to be more feasible considering later-age strength and economic viability. Interestingly, HVFA mixtures made with the landfilled fly ash used in this study were able to achieve high early strengths with water-to-cementitious materials ratio adjustment alone. As a result, these HVFA mixtures were also found to be less responsive to accelerators when compared to the fresh Class F fly ash, highlighting an important distinction between the materials despite the similarity in chemical composition.

42 ENGINEERING↗

DOE OSTI2025

Quantifications of growth rate and particle size of magnesium silicate hydrate cement using small‐angle X‐ray scattering

The focus of recent research on cement binders has shifted to alternatives such as magnesium silicate hydrate (M-S-H) to mitigate the environmental impact of conventional concrete production. However, a detailed understanding of the morphology and growth rate of M-S-H, which informs its applicability as a cementing agent, is lacking. These properties are important as they influence cement hydration and consequently the development of macroscopic properties. Here, in this study, the particle size distribution and growth rate of M-S-H synthesized by mixing aqueous stock solutions were analyzed using synchrotron-based small-angle X-ray scattering. The reaction solutions contained dissolved magnesium and silicon with concentrations ranging from 2 to 500 mM, corresponding to saturation indices with respect to M-S-H endmembers, M 0.75 -S-H and M 1.50 -S-H, between 5.8 and 10.3. The precipitation rates of M-S-H align with affinity-based kinetic models and can be described by the following equations: For M 0.75 -S-H: 𝑟 M 0.75 −S−H =10 −9.54±0.70 ⁢(Ω$^{0.59±0.08}_{M_{0.75}⁢\textrm{SH}}$−1), and for M 1.50 -S-H: 𝑟 M 1.50 −S−H =10 −7.56±0.37 ⁢(Ω$^{0.34±0.04}_{M_{1.50}⁢\textrm{SH}}$−1), where 𝑟 is the rate in mol/L/s, and Ω represents the saturation ratio with respect to M-S-H. Moreover, we observed that changing the [Mg]/[Si] ratio affects particle size, a trend that cannot be fully explained by changes in the saturation index alone. These insights are critical for improving the predictability and control of cementation in concrete that utilizes M-S-H-based binders.

M-S-H↗

DOE OSTI2024

A Multi-Streamline Approach for Upcycling PET into a Biodiesel and Asphalt Modifier

The non-degradable nature of petroleum-based plastics and the dependence on petroleum-based products in daily life and production are dilemmas of human development today. We hereby developed a plastic waste upcycling process to address these challenges. A multi-stream fraction strategy was developed to process poly (ethylene terephthalate) (PET) plastics into soluble and insoluble fractions. The soluble fraction was used as a sole carbon source for microbial fermentation to produce biodiesel precursor lipids with an appreciable bioconversion yield. The insoluble fraction containing fractionated polymers was used as the asphalt binder modifiers. The downsized PET additive improved the high-temperature performance of the asphalt binder by 1 performance grade (PG) without decreasing the low-temperature PG. Subsequent SEM imaging unveiled alterations in the micromorphology induced by PET incorporation. Further FTIR and 1 H NMR analysis highlighted the aromatic groups of PET polymers as a crucial factor influencing performance enhancement. The results demonstrated the multi-stream fraction as a promising approach for repurposing plastic waste to produce biodiesel and modify asphalt. Finally, this approach holds the potential to tackle challenges in fuel supply and enhance infrastructure resilience to global warming.

09 BIOMASS FUELS↗

DOE OSTI2024

Transport–Friendly Microstructure in SSC–MEA: Unveiling the SSC Ionomer–Based Membrane Electrode Assemblies for Enhanced Fuel Cell Performance

The significant role of the cathodic binder in modulating mass transport within the catalyst layer (CL) of fuel cells is essential for optimizing cell performance. This investigation focuses on enhancing the membrane electrode assembly (MEA) through the utilization of a short-side-chain perfluoro-sulfonic acid (SSC-PFSA) ionomer as the cathode binder, referred to as SSC-MEA. This study meticulously visualizes the distinctive interpenetrating networks of ionomers and catalysts, and explicitly clarifies the triple-phase interface, unveiling the transport-friendly microstructure and transport mechanisms inherent in SSC-MEA. The SSC-MEA exhibits advantageous microstructural features, including a better-connected ionomer network and well-organized hierarchical porous structure, culminating in superior mass transfer properties. Relative to the MEA bonded by long-side-chain perfluoro-sulfonic acid (LSC-PFSA) ionomer, noted as LSC-MEA, SSC-MEA exhibits a notable peak power density (1.23 W cm –2 ), efficient O 2 transport, and remarkable proton conductivity (65% improvement) at 65 °C and 70% relativity humidity (RH). These findings establish crucial insights into the intricate morphology-transport-performance relationship in the CL, thereby providing strategic guidance for developing highly efficient MEA.

25 ENERGY STORAGE↗

DOE OSTI2021

Role of Low Molecular Weight Polymers on the Dynamics of Silicon Anodes During Casting

This work probes the slurry architecture of a high silicon content electrode slurry with and without low molecular weight polymeric dispersants as a function of shear rate to mimic electrode casting conditions for poly(acrylic acid) (PAA) and lithium neutralized poly(acrylic acid) (LiPAA) based electrodes. Rheology coupled ultra-small angle neutron scattering (rheo-USANS) was used to examine the aggregation and agglomeration behavior of each slurry as well as the overall shape of the aggregates. The addition of dispersant has opposing effects on slurries made with PAA or LiPAA binder. With a dispersant, there are fewer aggregates and agglomerates in the PAA based silicon slurries, while LiPAA based silicon slurries become orders of magnitude more aggregated and agglomerated at all shear rates. The reorganization of the PAA and LiPAA binder in the presence of dispersant leads to a more homogeneous slurry and a more heterogeneous slurry, respectively. This reorganization ripples through to the cast electrode architecture and is reflected in the electrochemical cycling of these electrodes.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2023

Free‐Standing α‐MoO 3 / Ti 3 C 2 MXene Hybrid Electrode in Water‐in‐Salt Electrolytes

While transition‐metal oxides such as α‐MoO 3 provide high capacity, their use is limited by modest electronic conductivity and electrochemical instability in aqueous electrolytes. Two‐dimensional (2D) MXenes, offer metallic conductivity, but their capacitance is limited in aqueous electrolytes. Insertion of partially solvated cations into Ti 3 C 2 MXene from lithium‐based water‐in‐salt (WIS) electrolytes enables charge storage at positive potentials, allowing a wider potential window and higher capacitance. Herein, we demonstrate that α‐MoO 3 /Ti 3 C 2 hybrids combine the high capacity of α‐MoO 3 and conductivity of Ti 3 C 2 in WIS (19.8 m LiCl) electrolyte in a wide 1.8 V voltage window. Cyclic voltammograms reveal multiple redox peaks from α‐MoO 3 in addition to the well‐separated peaks of Ti 3 C 2 in the hybrid electrode. This leads to a higher specific charge and a higher rate capability compared to a carbon and binder containing α‐MoO 3 electrode. These results demonstrate that the addition of MXene to less conductive oxides eliminates the need for conductive carbon additives and binders, leads to a larger amount of charge stored, and increases redox capacity at higher rates. In addition, MXene encapsulated α‐MoO 3 showed improved electrochemical stability, which was attributed to the suppressed dissolution of α‐MoO 3 . The work suggests that oxide/MXene hybrids are promising for energy storage.

36 MATERIALS SCIENCE↗

DOE OSTI2021

3D printing of anisotropic Sm–Fe–N nylon bonded permanent magnets

Abstract Fabricating a bonded magnet with a near‐net shape in suitable thermoplastic polymer binders is of paramount importance in the development of cost‐effective energy technologies. In this work, anisotropic Sm 2 Fe 17 N 3 (Sm–Fe–N) bonded magnets are additively printed using SmFeN anisotropic magnetic particles in a polymeric binder polyamide‐12 (PA12). The anisotropic SmFeN bonded magnets are fabricated by Big Area Additive Manufacturing followed by post‐printing alignment in a magnetic field. Optimal post‐alignment results in an enhanced remanence of ∼0.68 T in PA12 reflected in a parallel‐oriented (aligned) measured direction. The maximum energy product achieved for the additively printed anisotropic bonded magnet of Sm–Fe–N in PA12 polymer is 78.8 KJ m −3 . Our results show advanced processing flexibility with 3D printing of the development of SmFeN nylon bonded magnets designed for applications with no critical rare earth magnets.

42 ENGINEERING↗