The present invention is intended to provide an annular insert molded article that suppresses contamination of a metal mold and generation of foreign matter without increase in material costs for an adhesive or contamination of a transfer jig, and has a high adhesion strength so that, when the annular insert molded article is attached to a rotating body, the adhesive does not peel off from the insert or remain as foreign matter in the rotating body, and a manufacturing method thereof.

An annular insert molded article 1 is manufactured by injection molding in a state where a thermoset resin adhesive A is applied to a joining surface of an annular insert 2 attachable to a rotating body to an annular plastic 3 and then the annular insert 2 and the annular plastic 3 are placed in a metal mold, wherein the range of the adhesive A applied to the annular insert 2 is a range not going beyond boundaries B1 and B2 with the annular plastic 3 by more than 3 mm, and the range does not include a portion C of the annular insert 2 to be fitted with the rotating body.

A method for producing a bonded permanent magnet by additive manufacturing, the method comprising: (i) incorporating components of a reactive precursor material into an additive manufacturing device, the reactive precursor material comprising an amine component, an isocyanate component, and particles having a permanent magnetic composition; and (ii) mixing and extruding the crosslinkable reactive precursor material through a nozzle of the additive manufacturing device and depositing the extrudate onto a substrate under conditions where the extrudate is permitted to cure, to produce a bonded permanent magnet of desired shape. The resulting bonded permanent magnet and articles made thereof are also described.

The present disclosure describes three-dimensional printing kits, systems for three-dimensional printing, and methods of three-dimensional printing. In one example, a three-dimensional printing kit can include a particulate build material and a binding agent. The particulate build material can include metal particles. The binding agent can include a polyhydroxy polyol and a water-dispersible blocked polyisocyanate having multiple blocked isocyanate groups. The blocked isocyanate groups can include a blocking group bonded to the carbon atom of the blocked isocyanate group through a labile bond breakable by heating to a deblocking temperature. Breaking the labile bond can produce a released blocking group reacted with hydrogen and an isocyanate group.

Fabricating a stimuli-responsive object includes providing a first feedstock and a second feedstock to a print head, extruding a multi-sublayer extrudate from the print head, depositing the multi-sublayer extrudate on a substrate to yield an extrudate layer, and curing the extrudate layer to yield the stimuli-responsive object. A first feedstock, a second feedstock, or both includes one or more stimuli-responsive polymer composites, and the print head includes n multipliers. A multi-sublayer extrudate includes 2.sup.(n+1)/2 sublayers of a first feedstock and 2.sup.(n+1)/2 sublayers of a second feedstock, and 2.sup.(n+1)/2?1 sublayers of a first feedstock are in direct contact with two sublayers of a second feedstock. A stimuli-responsive polymer composite includes thermally actuated polymers. A stimuli-responsive polymer composite includes thermoplastic polymers. A stimuli-responsive polymer composite includes magnetic material. A magnetic material includes iron oxide nanoparticles.

A consumable filament for use in an extrusion-based additive manufacturing system, where the consumable filament comprises a core portion of a matrix of a first base polymer and particles dispersed within the matrix, and a shell portion comprising a same or a different base polymer. The consumable filament is configured to be melted and extruded to form roads of a plurality of solidified layers of a three-dimensional part, and where the roads at least partially retain cross-sectional profiles corresponding to the core portion and the shell portion of the consumable filament and retain the particles within the roads of the printed part and do not penetrate the outer surface of the shell portion.

A consumable filament for use in an extrusion-based additive manufacturing system, where the consumable filament comprises a core portion of a matrix of a first base polymer and particles dispersed within the matrix, and a shell portion comprising a same or a different base polymer. The consumable filament is configured to be melted and extruded to form roads of a plurality of solidified layers of a three-dimensional part, and where the roads at least partially retain cross-sectional profiles corresponding to the core portion and the shell portion of the consumable filament and retain the particles within the roads of the printed part and do not penetrate the outer surface of the shell portion.

A method for producing a bonded permanent magnet by additive manufacturing, comprising: (i) incorporating components of a solid precursor material into at least one deposition head of at least one multi-axis robotic arm of a big area additive manufacturing (BAAM) system, the components of the solid precursor material comprising a thermoplastic polymer and hard magnetic powder; said deposition head performs melting, compounding, and extruding functions; and said BAAM system has an unbounded open-air build space; and (ii) depositing an extrudate of said solid precursor material layer-by-layer from said deposition head until an object constructed of said extrudate is formed, and allowing the extrudate to cool and harden after each deposition, to produce the bonded permanent magnet. The resulting bonded permanent magnet and articles made thereof are also described.

A method for producing magnet-polymer pellets useful as a feedstock in an additive manufacturing process, comprising: (i) blending thermoplastic polymer and hard magnetic particles; (ii) feeding the blended magnet-polymer mixture into a pre-feed hopper that feeds directly into an inlet of a temperature-controlled barrel extruder; (iii) feeding the blended magnet-polymer mixture into the barrel extruder at a fixed feed rate of 5-20 kg/hour, wherein the temperature at the outlet is at least to no more than 10 C. above a glass transition temperature of the blended magnet-polymer mixture; (iv) feeding the blended magnet-polymer mixture directly into an extruding die; (v) passing the blended magnet-polymer mixture through the extruding die at a fixed speed; and (vi) cutting the magnet-polymer mixture at regular intervals as the mixture exits the extruding die at the fixed speed. The use of the pellets as feed material in an additive manufacturing process is also described.

A magnetic sheet comprises, by vol. %, FeSiAl alloy flat powder: 36% or more. The FeSiAl alloy flat powder comprises, by wt %, 9.3%Si9.7%, 5.7%Al6.1%, and remaining Fe. The FeSiAl alloy flat powder has: an aspect ratio in a range of 20 or more and 50 or less; a 50% particle size D.sub.50 in a range of 50 m or more and 100 m or less; and a coercivity Hc of 60 A/m or less. The magnetic sheet has a temperature characteristic of permeability measured at 1 MHz exhibiting a maximum value in a range of 0 C. or more and 40 C. or less.

Disclosed are a soft bistable magnetic actuator, a fabrication method thereof, a fatigue testing device, and an auto underwater vehicle. The method for fabricating the soft bistable magnetic actuator includes the following operations: casting a soft precursor by injection molding, wherein the soft precursor consists of a soft deformable portion and a soft peripheral portion surrounded, the soft deformable portion is made of magnetic particles and polymer, and the soft peripheral portion is made of a magnetic particle, a mixture of organic liquid, and polymer; and extracting the organic liquid by an organic solvent shrinks the soft peripheral portion, buckles the soft deformable portion towards one side.