Magnetic Fields Cut Flaws in 3D-Printed Metal Components by 80%

A new technique using magnets during laser-based 3D printing stabilizes keyhole formation, reducing defects and improving durability for critical applications.

• Researchers from UCL and the University of Greenwich developed a method to reduce flaws in 3D-printed metal components using magnetic fields.
• High-speed X-ray imaging at the Advanced Photon Source in Chicago revealed that applying a magnetic field stabilizes the molten metal, reducing pore formation by 80%.
• The technique addresses long-standing challenges in laser-based 3D printing, where unstable keyholes in molten metal often lead to defects in the final product.
• The findings could improve the durability and quality of 3D-printed components used in safety-critical industries like aerospace, Formula 1, and medical implants.
• While promising, integrating magnetic fields into industrial 3D printing processes will require overcoming technical challenges, with widespread adoption still years away.

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