Running Head: THREE DIMENSIONAL MAGNETIC MODELING WITH FERROFLUIDS 1
Three Dimensional Magnetic Modeling with Ferrofluids
Anna Sullivan, Brad Riotto, Harrison Shipp, Kinsly Smith, Nick Pampe
HUNCH/ Jackson Hole High School
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Introduction
The researchers are the Jackson Hole High School HUNCH team from Jackson, Wyoming. We
used a wax based ferrofluid in our experiment in order to create three dimensional parts in a zero
gravity environment. Our work this year served as a proof of concept and we hope to take the
idea further in the coming years. The ultimate goal of the experiment is to develop a process to
create parts on the ISS by only having the magnets and the materials. This would limit the need
for bringing extra parts into space.
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Abstract
In order to shape parts, we used a wax based ferrofluid that is solid at room temperature but can
be melted to a liquid. The ferrofluid was sealed between one Lexan sheet and one aluminum
sheet. A magnet and a heating strip were attached to the outside of the aluminum sheet. The
slides were heated to melt the carrier material. Once the substance became a liquid, it shaped
itself to the magnetic field. After the ferrofluid was completely shaped, we cooled the carrier
material using ice packs that were attached to the top of the slides, and waited until the fluid
hardened to a solid. We examined the parts for consistency and quality.
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Statement of the Research Problem
According to our research, no method has been developed to three-dimensionally model in
space. It is not only difficult to use three dimensional printers in a microgravity environment, but
they are large and bulky. In order to prepare for part failure on the ISS, extra parts would have to
be brought into space. This takes up room, payload weight, and costs more money.
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Method
The team began by researching problems that astronauts face on the ISS. Through this
research, we discovered that there is currently no way to create parts in micro-gravity. We
discovered an article by Markus Zahn, the director of electrical engineering at MIT, who used
wax-based ferrofluids to create Nano parts. This article suggested the plausibility of using
magnetic modeling in a zero-g environment. We decided to take this idea and apply it to the
macroscopic scale. We researched several forms of carrier materials, and from experimentation,
found that wax was the material best suited for our applications. In our experiment, the waxbased ferrofluid is placed between a Lexan and aluminum slides that are held together by bolts
and spaced by 1/8” washers. There is parchment paper around the wax to prevent adhesion to the
slides. A heating strip is attached to the outside face of the aluminum sheet. A washer shaped
neodymium magnet is then attached to the center of the heating strip using thermal tape. There
are four slides attached aluminum side down to a 3D printed ABS plastic test bed. Two heating
strips are plugged into a DC power supply, set to 35V and 200mA, to heat up and melt the wax.
Gel ice packs are then removed from a cooler and attached to the Lexan sheet with Velcro. This
cools the wax and returns it to a solid. We hypothesized that we would create washer shaped wax
parts that match the shape of the magnet. We predicted that this would happen regardless of the
amount of gravity affecting it, due to the presence of the magnet holding the wax in place. We
tested the entire experiment at different orientations to ensure that gravity was not aiding our
results. In 1g, we successfully created multiple parts that matched the magnet. These parts had
small spikes on one side that matched the magnetic field of the magnet. Although the parts were
not perfect, our hypothesis was proven correct.
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Results
In 1g, we successfully created multiple parts that matched the magnet. Our hypothesis
was proved right. In 0g and hyper-g, washer shaped parts were created but there were waves as
well as spikes on the tops of the parts. However, parts with waves were more frequent than parts
with spikes. After further testing in the lab, we found that the waves were caused by the new
parchment paper that we used on the flight, creating a variable. Even though the parts were
slightly different in zero-g than they were in 1-g, we were still able to create parts. Our
hypothesis was proved right for 0g and hyper-g.
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Discussion
Our main challenge was finding the right carrier material for the ferrofluid. The team had
to find a material that was miscible with iron particles and a surfactant, but that could be fully
melted to a liquid under 140 ° F. Although we made a wax based ferrofluid in our lab, we
discovered that the ferrowax that a company called FerroTec makes, worked best for our
experiment due to its lack of residue and strong magnetic capabilities. We worked through other
setbacks along the way, such as what heater to use, how much material is necessary between the
slides, and the most effective way to cool the slides, but were able to overcome these problems.
Our biggest success was being prepared and completely an experiment that worked as we
expected.
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Conclusion
We now believe that the concept of three-dimensional magnetic modeling in space is
plausible. Creating parts on a larger scale will be more difficult, but we can now start working on
future applications. We will have to take into consideration the heating method for larger parts,
the containment for greater amounts of ferrowax, and the placements of magnets. We also
learned that is it difficult to make ferrofluids with different carrier materials than we anticipated.
Since our experiment consisted of wax parts, this will prove to be challenging when we begin to
make larger parts with sturdier carrier materials. If we were to retest our experiment, we would
want to have a faster and more effective cooling method. This way the wax will cool and harden
during 0g only. Our experiment could potentially make it possible to create any part on the ISS
that is necessary using only magnets and materials. This will eliminate the need to bring extra
parts on the ISS and could allow for longer and more adventurous missions. For our outreach
items we brought jelly beans, a Frisbee, and sticky frogs to see how they acted in a micro-gravity
environment.
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THREE DIMENSIONAL MAGNETIC MODELING WITH FERROFLUIDS
Acknowledgments
We would like to thank Mr. Brumsted, Florance Gold, Vanessa Rene, Vernier
Instruments, Scott Crisp, Bruce Bent, and Gary Duquette. Without their help, this experiment
would not have been possible.
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