A Review on Microstructure and Magnetic Property Control in Additively Manufactured Magnetic Materials

Additive manufacturing (AM) is revolutionizing the production of magnetic materials by enabling the fabrication of components with complex geometries and tailored functionalities that are challenging to achieve with conventional methods. AM enables precise control over microstructure, defect distribution, and material orientation, which directly affects mechanical and magnetic properties. Magnetic alloys and composites, including Fe–X (X = Si, Ni, and Co), NdFeB, and SmCo, are vital for transformers, electric machines, aircraft components, and electric vehicle magnets, necessitating low coercivity, high permeability, and regulated electrical resistivity. Recent advancements in AM have concentrated on refining processing settings, designing feedstock, and improving post‐processing procedures to enhance structural integrity and functional characteristics. This review primarily focuses on direct metal AM techniques, with emphasis on Fe‐based soft magnetic alloys and selected permanent magnet systems, particularly in electrical and electromagnetic applications. In addition to highlighting the ability of AM to alter the manufacturing of magnetic components while simultaneously addressing existing limitations, emerging trends, and potential research areas are also emphasized.