Embedded Parts: Fluxgate Sensor

The case study describes a new method for constructing the fluxgate sensor using Nano Dimension's Dragonfly LDM 2.0 Additive Manufacturing System. The objective is to fabricate a sensor with the embedded coil core . This design may be realised by two methods for embedding the core: direct printing (currently not possible due to material constraints) and embedding metalic core during the print time into the printed cavity.

As explained, this allows more flexibility to design a coil using traditional eCAD software or 3D CAD systems. The coil embedding process is multi-staged, with a detailed description of each phase.

The developed fluxgate sensor shows superior performance, achieving a sensitivity of around 7,500 V/T at an excitation frequency of 29 kHz, with noise levels as low as 14 pT/√Hz using advanced shielding. Due to the success of the first-generation sensor, a second-generation design is now in development.

• Innovative 3D Printers: The project showcases the versatility of Nano Dimension's Dragonfly LDM system and how it can be utilized for advanced additive manufacturing to develop intricate electronics with embedded elements.
• Design of an Embedded Coil: Two methods for embedding the coil core inside the sensor are proposed, focusing on using 3D printing technology to innovate the fabrication process for advanced electronics.
• Sensor Performance: It demonstrated high sensitivity and low noise levels, making it suitable for precise magnetic field measurements.
• Partnership: The joint project highlights how academic and industrial partnerships, like CTU in Prague and Nano Dimension, can drive innovation.