3D Printing Permanent Magnets

Researchers at TU Wien wanted to create magnets with exactly the right magnetic field for a particular application. Their solution? 3D printing of magnets. Previously, it has been difficult to produce permanent magnets with a specific shape of the magnetic field. The resulting magnets will be a boon to magnetic sensor construction.

Previously, after designing a magnet with a specific shape and magnetic field, a researcher would have to create tooling for injection molding. This is expensive and time-consuming and often not worth it for small quantities of magnets.

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Ultra Simple Magnetic Levitator

Want to build a magnetic levitator in under two hours? With a total of 7 parts, including the coil, it just cannot get simpler than what [How-ToDo] shows here! It is not only an extremely simple circuit, it also has the advantage of using only discrete components: a MOSFET, hall effect sensor, diode and two resistors, that’s it.

The circuit works by sensing the position of the levitating magnet, using the hall effect sensor , then turns the coil on and off in response via the MOSFET. The magnet moves upwards when the coil is energized and falls down when it is not. This adjustment is made hundreds of times a second, and the result is that the magnets stays floating in mid air.

This is the kind of project that can make a kid get interested in science: it combines easy construction with visually amazing behavior, and can teach you basic concepts (electromagnetism and basic electronics in this case). Excellent for a school project.

For the more advanced enthusiast, more sophisticated levitator design based on an Atmega8 micro-controller will be of interest.

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Magnets for a Machinist

We’re not sure if [Stefan Gotteswinter] ever makes anything but tools to make more tools in his shop. This nice set of toolmaker’s magnets are no exception to the trend.

We can gather that [Stefan] is a professional machinist by trade. Like all professionals who do the same thing for work and play, he was spoiled by the nicer tools at work. One tool in particular, a toolmaker’s magnet, always came in handy. These are strong magnets that have been ground flat, square, and parallel.

He really only needed one magnet, so he started to build a 20 x 20 x 100 mm one. It would be made out of alternating mild steel and brass plates. The steel plates would have a hole drilled through them and he’d place a correctly oriented magnet in the middle. It would all be clamped and glued together.

The build was going pretty well when he decided that he couldn’t really trust the glue alone. He had just begun grinding, but decided to switch to a quick drilling operation. Two brass rods through the whole assembly would be enough to hold it together. He started drilling, and then, suddenly, he had two magnets.

The assembly had broken in half. He decided that, all things considered, two 20 x 20 x 50 mm magnets were also handy. So he completed the drilling, and ground the new set of magnets to be a perfect match to each other.  In the end he had a tool that looks just as expensive as the commercial option. There is also a video series on the magnets, part 1 and part 2, viewable after the break.

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Electric Train Demonstrator

If you ever want to pique a kid’s interest in technology, it is best to bring out something simple, yet cool. There was a time that showing a kid how a crystal radio could pull in a radio station from all the way across town fit the bill. Now, that’s a yawner as the kid probably carries a high-tech cell phone with a formidable radio already. Your latest FPGA project is probably too complicated to grasp, and your Arduino capacitance meter is–no offense–too boring to meet the cool factor criterion.

There’s an old school project usually called an “electromagnetic train” that works well (Ohio State has a good write up about it as a PDF file). You coil some bare copper wire around a tubular form to make a tunnel. Then a AAA battery with some magnets make the train. When you put the train in the tunnel, the magnetic forces propel the train through the tunnel. Well, either that or it shoots it out. If that happens, turn the train around and try again. There’s a few of these in Internet videos and you can see one of them (from [BeardedScienceGuy]) below.

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Homemade EDM Can Cut Through Difficult Materials Like Magnets With Ease

Many years ago [ScorchWorks] built an electrical-discharge machining tool (EDM) and recently decided to write about it. And there’s a video embedded after the break.

The build is based on the designs described in the book “Build an EDM” by Robert Langolois. An EDM works by creating lots of little electrical discharges between an electrode in the desired shape and a material underneath a dielectric solvent bath. This dissolves the material exactly where the operator would like it dissolved. It is one of the most precise and gentle machining operations possible.

His EDM is built mostly out of found parts. The power supply is a microwave oven transformer rewired with 18 gauge wire to drop the voltage to sixty volts instead of the oven’s original boost to 1.5kV.  The power resistor comes from a dryer element robbed from a unit sitting beside the road. The control board was etched using a hand traced schematic on the copper with a Sharpie.

The linear motion element are two square brass tubes, one sliding inside the other. A stepper motor slowly drives the electrode into the part. Coolant is pumped through the electrode which is held by a little 3D printed part.

The EDM works well, and he has a few example parts showing its ability to perform difficult cuts. Things such as a hole through a razor blade., a small hole through a very small piece of thick steel, and even a hole through a magnet.

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Real World Race Track is Real Hack

[Rulof] never ceases to impress us with what he comes up with and how he hacks it together. Seriously, how did he even know that the obscure umbrella part he used in this project existed, let alone thought of it when the time came to make a magnet mount? His hack this time is a real world, tabletop race track made for his little brother, and by his account, his brother is going crazy for it.

His race track is on a rotating table and consists of the following collection of parts: a motor, bicycle wheel, casters from a travel bag, rubber bands (where did he get such large ones?), toy car and steering wheel from his brother, skateboard wheels, the aforementioned umbrella part and hard drive magnets. In the video below we like how he paints the track surface by holding his paint brush fixed in place and letting the track rotate under it.

From the video you can see the race track has got [Rulof] hooked. Hopefully he lets his brother have ample turns too, but we’re not too sure. Some additions we can imagine would be robotics for the obstacles, lighting, sounds and a few simulated explosion effects (puffs of flour?).

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3D Carver Makes Magnetic Fields Visible

The history of science is full of examples when a 3D physical model led to a big discovery. But modelling something that’s actually invisible can be tough. Take magnetic fields – iron filings on a card will give you a 2D model, but a 3D visualization of the field would be much more revealing. For that job, this magnetic field following 3D carving machine is just the thing.

What started out as a rapid prototyping session with servos and hot glue ended up as quick and dirty 3D carving rig for [Frits Lyneborg]. The video shows his thought progression and details how he went from hot glue and sticks to LEGO Technics parts and eventually onto Makerbeam extrusions for the frame of his carver. A probe with a Hall effect sensor is coupled to a motor spinning a bit that cuts into a block of floral foam. A microcontroller keeps the Hall sensor a more or less fixed distance from a rare-earth magnet, resulting in a 3D model of the magnetic field in the foam, as well as a mess of foam nubbles. Despite a few artifacts due to in-flight adjustments of the rig, the field presents clearly in the block as two large lobes.

Carving foam isn’t the only way to visualize a magnetic field in three dimensions, of course. If you’d rather have a light show based on the local magnetic field, try this 3D compass build we covered a while back.

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