  Isotropic bonded magnets with a high loading fraction of 70 vol.% Nd-Fe-B are
fabricated via an extrusion-based additive manufacturing, or 3D printing system
that enables rapid production of large parts for the first time. The density of
the printed magnet is 5.15 g/cm3. The room temperature magnetic properties are:
intrinsic coercivity Hci = 8.9 kOe (708.2 kA/m), remanence Br = 5.8 kG (0.58
Tesla), and energy product (BH)max = 7.3 MGOe (58.1 kJ/m3). The as-printed
magnets are then coated with two types of polymers, both of which improve the
thermal stability at 127 {\deg}C as revealed by flux aging loss measurements.
Tensile tests performed at 25 {\deg}C and 100 {\deg}C show that the ultimate
tensile stress (UTS) increases with increasing loading fraction of the magnet
powder, and decreases with increasing temperature. AC magnetic susceptibility
and resistivity measurements show that the 3D printed Nd-Fe-B bonded magnets
exhibit extremely low eddy current loss and high resistivity. Finally, we show
that through back electromotive force measurements that motors installed with
3D printed Nd-Fe-B magnets exhibit similar performance as compared to those
installed with sintered ferrites.
