This presentation discusses the cost effective fabrication of soft and hard magnetic materials using cold spray additive manufacturing. This technique allows for 3D build-up of complex shapes permitting fabrication of high complexity motor designs for enhanced performance. Combination of sprayed soft and hard magnetic materials opens up synergetic design possibilities for additional performance gain and cost savings. Measured hard magnetic properties (coercivity and remanence), soft magnetic properties (permeability and losses) and mechanical properties (adhesion and cohesion) will be presented. Use of the materials for the realization of motor prototypes will be discussed.
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