Researchers at Tomsk State University (TSU) have developed a magnetic 3D printing filament capable of selectively absorbing electromagnetic radiation around 49 GHz. By blending a polymer called ASA with barium hexaferrite powder, the team created a composite material that retains its magnetic properties not only during printing but also in the ultra-high-frequency range.
The TSU lab first produced the filament and then verified that the electromagnetic characteristics survived the 3D printing process intact. This is a critical step because composites often perform well as raw materials but lose key properties after being printed due to layer structures, print settings, and geometry. The magnetic response varies with the amount of barium hexaferrite incorporated into the filament.
As is common with such composites, there is a trade-off: increasing the ferrite powder enhances the electromagnetic effects but reduces mechanical strength. This means different filament formulations will be tailored for specific uses-one mix might be perfect for a keychain, another for a radio electronics component.
TSU handles the entire process in-house, from synthesizing the ferrite powders to extruding the filament on their own production line. This is somewhat unusual for academic labs, which typically buy base polymer filaments and add powders afterward.
Interest in multifunctional 3D printing materials is growing beyond academia. According to the Wohlers Report, the global 3D printing market has surpassed $20 billion, with increasing demand for functional materials in electronics, healthcare, and industrial applications-far beyond simple plastics for enclosures. Similar research on 3D-printed ferrite composites is underway in China, the US, and Europe, targeting EMI shielding, miniantennas, and microwave components.
TSU aims to expand beyond a single filament type to create a whole lineup with varied electromagnetic profiles. If they achieve consistent, scalable production, 3D printing could start producing not just consumer goods but functional radioelectronic parts like filters, sensors, and antennas. The biggest challenge will be maintaining uniform properties batch after batch.