Processing-induced magnetic softening in high-loading printable composites for additive manufacturing

filament quality, processability, and functional performance. Yet, processing-driven advances in AM can redefine this design space, enabling unprecedented filler loadings, broader material compatibility, and scalable fabrication beyond conventional flexible metastructures. Here, we introduce a versa...

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Autores: Guerrero Muñoz, Gloria, Revuelta Losada, Jorge, Law, Jia Yan, Guisado Arenas, Elisa, Moreno Ramírez, Luis Miguel, Sánchez Poncela, Manuel, Franco García, Victorino
Tipo de recurso: artículo
Estado:Versión publicada
Fecha de publicación:2026
País:España
Institución:Universidad de Sevilla (US)
Repositorio:idUS. Depósito de Investigación de la Universidad de Sevilla
OAI Identifier:oai:dnet:idus________::c2dc8a141dac48f5c08abca7705d4097
Acceso en línea:https://hdl.handle.net/11441/186542
https://doi.org/10.1007/s42114-026-01715-9
Access Level:acceso abierto
Palabra clave:Additive manufacturing
Magnetic filaments
Fused fabrication filament
Soft magnetic properties
Mechanical/secondary properties
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spelling Processing-induced magnetic softening in high-loading printable composites for additive manufacturingGuerrero Muñoz, GloriaRevuelta Losada, JorgeLaw, Jia YanGuisado Arenas, ElisaMoreno Ramírez, Luis MiguelSánchez Poncela, ManuelFranco García, VictorinoAdditive manufacturingMagnetic filamentsFused fabrication filamentSoft magnetic propertiesMechanical/secondary propertiesfilament quality, processability, and functional performance. Yet, processing-driven advances in AM can redefine this design space, enabling unprecedented filler loadings, broader material compatibility, and scalable fabrication beyond conventional flexible metastructures. Here, we introduce a versatile feedstock-engineering strategy that fabricates magnetic composite filaments with high filler contents while maintaining homogeneity, printability, and performance. By systematically comparing three polymer matrices with two classes of soft magnetic powders, we report the critical interplay among matrix chemistry, filler morphology, and processing conditions, achieving magnetic filaments at high loadings (up to 61 wt% in rigid and 52 wt% in flexible systems), well above commercial standards (~ 40 wt%). Polyethylene terephthalate yields rigid, defect-free filaments at high loadings, whereas thermoplastic polyurethane uniquely enables mechanically flexible, magnetically functional filaments. Structural analyses confirm uniform filler dispersion and preservation of the amorphous or crystalline characters of the powders, while magnetic characterization uncovers an unexpected processinginduced magnetic softening: extrusion reduces coercivity relative to raw powders. This counterintuitive softening transforms extrusion from a passive fabrication step into a functional design tool. Proof-of-concept flexible demonstrations, including flexible actuators and magnetic grippers, exhibit magnetic field-responsive deformation and flux-guided manipulation, validating multifunctionality. The results establish a new design principle, processing-induced property enhancement, which enables AM of magnetically active yet mechanically compliant and reconfigurable systems for soft robotics and electromagnetic control. This scalable, polymer-independent method expands material and functional options for engineering multifunctional composites with structural integrity, mechanical flexibility, and enhanced functionality.SpringerFísica de la Materia CondensadaAgencia Estatal de Investigación. EspañaAir Force Office of Scientific Research. United States2026info:eu-repo/semantics/articleinfo:eu-repo/semantics/publishedVersionapplication/pdfapplication/pdfhttps://hdl.handle.net/11441/186542https://doi.org/10.1007/s42114-026-01715-9reponame:idUS. Depósito de Investigación de la Universidad de Sevillainstname:Universidad de Sevilla (US)InglésAdvanced Composites and Hybrid Materials, 9 (2), 150. PID2023-146047OB-I00FA8655-21-1-7044info:eu-repo/semantics/openAccessoai:dnet:idus________::c2dc8a141dac48f5c08abca7705d40972026-06-17T12:51:07Z
dc.title.none.fl_str_mv Processing-induced magnetic softening in high-loading printable composites for additive manufacturing
title Processing-induced magnetic softening in high-loading printable composites for additive manufacturing
spellingShingle Processing-induced magnetic softening in high-loading printable composites for additive manufacturing
Guerrero Muñoz, Gloria
Additive manufacturing
Magnetic filaments
Fused fabrication filament
Soft magnetic properties
Mechanical/secondary properties
title_short Processing-induced magnetic softening in high-loading printable composites for additive manufacturing
title_full Processing-induced magnetic softening in high-loading printable composites for additive manufacturing
title_fullStr Processing-induced magnetic softening in high-loading printable composites for additive manufacturing
title_full_unstemmed Processing-induced magnetic softening in high-loading printable composites for additive manufacturing
title_sort Processing-induced magnetic softening in high-loading printable composites for additive manufacturing
dc.creator.none.fl_str_mv Guerrero Muñoz, Gloria
Revuelta Losada, Jorge
Law, Jia Yan
Guisado Arenas, Elisa
Moreno Ramírez, Luis Miguel
Sánchez Poncela, Manuel
Franco García, Victorino
author Guerrero Muñoz, Gloria
author_facet Guerrero Muñoz, Gloria
Revuelta Losada, Jorge
Law, Jia Yan
Guisado Arenas, Elisa
Moreno Ramírez, Luis Miguel
Sánchez Poncela, Manuel
Franco García, Victorino
author_role author
author2 Revuelta Losada, Jorge
Law, Jia Yan
Guisado Arenas, Elisa
Moreno Ramírez, Luis Miguel
Sánchez Poncela, Manuel
Franco García, Victorino
author2_role author
author
author
author
author
author
dc.contributor.none.fl_str_mv Física de la Materia Condensada
Agencia Estatal de Investigación. España
Air Force Office of Scientific Research. United States
dc.subject.none.fl_str_mv Additive manufacturing
Magnetic filaments
Fused fabrication filament
Soft magnetic properties
Mechanical/secondary properties
topic Additive manufacturing
Magnetic filaments
Fused fabrication filament
Soft magnetic properties
Mechanical/secondary properties
description filament quality, processability, and functional performance. Yet, processing-driven advances in AM can redefine this design space, enabling unprecedented filler loadings, broader material compatibility, and scalable fabrication beyond conventional flexible metastructures. Here, we introduce a versatile feedstock-engineering strategy that fabricates magnetic composite filaments with high filler contents while maintaining homogeneity, printability, and performance. By systematically comparing three polymer matrices with two classes of soft magnetic powders, we report the critical interplay among matrix chemistry, filler morphology, and processing conditions, achieving magnetic filaments at high loadings (up to 61 wt% in rigid and 52 wt% in flexible systems), well above commercial standards (~ 40 wt%). Polyethylene terephthalate yields rigid, defect-free filaments at high loadings, whereas thermoplastic polyurethane uniquely enables mechanically flexible, magnetically functional filaments. Structural analyses confirm uniform filler dispersion and preservation of the amorphous or crystalline characters of the powders, while magnetic characterization uncovers an unexpected processinginduced magnetic softening: extrusion reduces coercivity relative to raw powders. This counterintuitive softening transforms extrusion from a passive fabrication step into a functional design tool. Proof-of-concept flexible demonstrations, including flexible actuators and magnetic grippers, exhibit magnetic field-responsive deformation and flux-guided manipulation, validating multifunctionality. The results establish a new design principle, processing-induced property enhancement, which enables AM of magnetically active yet mechanically compliant and reconfigurable systems for soft robotics and electromagnetic control. This scalable, polymer-independent method expands material and functional options for engineering multifunctional composites with structural integrity, mechanical flexibility, and enhanced functionality.
publishDate 2026
dc.date.none.fl_str_mv 2026
dc.type.none.fl_str_mv info:eu-repo/semantics/article
info:eu-repo/semantics/publishedVersion
format article
status_str publishedVersion
dc.identifier.none.fl_str_mv https://hdl.handle.net/11441/186542
https://doi.org/10.1007/s42114-026-01715-9
url https://hdl.handle.net/11441/186542
https://doi.org/10.1007/s42114-026-01715-9
dc.language.none.fl_str_mv Inglés
language_invalid_str_mv Inglés
dc.relation.none.fl_str_mv Advanced Composites and Hybrid Materials, 9 (2), 150.
PID2023-146047OB-I00
FA8655-21-1-7044
dc.rights.none.fl_str_mv info:eu-repo/semantics/openAccess
eu_rights_str_mv openAccess
dc.format.none.fl_str_mv application/pdf
application/pdf
dc.publisher.none.fl_str_mv Springer
publisher.none.fl_str_mv Springer
dc.source.none.fl_str_mv reponame:idUS. Depósito de Investigación de la Universidad de Sevilla
instname:Universidad de Sevilla (US)
instname_str Universidad de Sevilla (US)
reponame_str idUS. Depósito de Investigación de la Universidad de Sevilla
collection idUS. Depósito de Investigación de la Universidad de Sevilla
repository.name.fl_str_mv
repository.mail.fl_str_mv
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