Experimental Implementation of a Magnetic Levitation System for Laser-Directed Energy Deposition via Powder Feeding Additive Manufacturing Applications

Magnetic levitation and additive manufacturing (AM) are two fields of significant interest in academic research. The use of non-contact forces for magnetic levitation techniques provides opportunities for adoption within the AM environment. The key goal of this article is to experimentally validate the implementation of a magnetic levitation system for Laser-Directed Energy Deposition via Powder Feeding (LDED-PF) Additive Manufacturing applications. Through simulations (conducted in ANSYS Maxwell) and experimental implementation, the levitation system's stability is tested under a variety of different conditions. The experimental implementation highlights the feasibility of a magnetic levitation system for LDED-PF applications. The levitation system developed is capable of the suspension of non-magnetic materials. The system is also able to maintain stable levitation for extended periods of time. The incorporation of the levitation system into the AM environment may result in an increased maneuverability of non-clamped structures for AM deposition operations.