IMDEA Materials researchers have successfully analyzed the crystallization kinetics of Finemet-type Fe-Si-B-Nb-Cu alloys during the Laser Powder Bed Fusion (LPBF) process. Conducted under the AM2SoftMag project, the study focuses on controlling the microstructure of soft magnetic components to optimize their electromagnetic performance. The team, led by researchers at the Madrid-based institute, utilized high-resolution characterization techniques to map how rapid solidification cycles in LPBF influence the formation of nanocrystalline phases within the amorphous matrix. This work provides a technical framework for producing complex, high-permeability magnetic cores that are difficult to manufacture using traditional casting or stamping methods.

The ability to print soft magnetic materials with tailored microstructures addresses a critical bottleneck in the production of high-efficiency electric motors and power electronics. While soft magnetic alloys like Finemet are standard in traditional manufacturing, their performance is highly sensitive to thermal history, making them notoriously difficult to process via LPBF without losing magnetic properties. This research positions IMDEA Materials as a key contributor to the growing segment of functional material development for AM, competing with established powder metallurgy firms that are currently struggling to bridge the gap between material science and high-speed laser processing. As the demand for miniaturized, high-frequency magnetic components grows, the ability to control phase transformation at the melt-pool level is essential for commercial viability.

For manufacturers, this study confirms that precise control over laser parameters is the primary lever for maintaining the nanocrystalline structure required for low-loss magnetic performance. Future efforts must now focus on scaling these findings from laboratory coupons to functional, net-shape components while ensuring consistent magnetic permeability across larger build volumes. Users should prioritize the integration of these material-specific process parameters into their existing LPBF software workflows to minimize unwanted phase transitions during production.