Deep X-Ray Lithography Based Fabrication of Rare-Earth Based Permanent Magnets and their Applications to Microactuators

Precision high aspect-ratio micro molds constructed by deep x-ray lithography have been used to batch fabricate accurately shaped bonded rare-earth based permanent magnets with features as small as 5 microns and thicknesses up to 500 microns. Maximum energy products of up to 8 MGOe have been achieved with a 20%/vol. epoxy bonded melt-spun isotropic Nd2Fe14b powder composite. Using individually processed sub- millimeter permanent sections multipole rotors have been assembled. Despite the fact that these permanent magnet structures are small, their magnetic field producing capability remains the same as at any scale. Combining permanent magnet structures with soft magnetic materials and micro-coils makes possible new and more efficient magnetic microdevices