Summary:
UCLA researchers have created a cost-effective method to prototype complex magnet arrays using simple cube magnets and 3D-printed supports, enabling faster and safer development of advanced robotic, medical, and mechatronic systems.
Background:
Permanent magnets are widely used in mechatronic systems, such as motors, robotic grippers, medical devices, and sensors, because they can transfer force and energy without requiring direct contact. In many advanced applications, engineers design magnet arrays, where multiple magnets are arranged in specific orientations to shape magnetic fields for stronger, more precise, or controllable effects. A well-known example is the Halbach array, which channels magnetic force to one side for efficiency and control.
While these magnet arrays unlock powerful capabilities for robotics and other technologies, they are very difficult and expensive to manufacture. Custom magnet shapes require specialized tooling, rare earth materials, and complex assembly, which drive costs into the thousands of dollars. In practice, researchers and developers are often forced to use simpler, less optimized designs that limit system performance. Furthermore, assembling large arrays of strong magnets is unstable and hazardous because of the forces between individual magnets, making prototyping risky and time-consuming. This gap between computer-designed arrays and real-world prototypes slows innovation and adoption of advanced magnetic systems.
Innovation:
To address these limitations in the state of the art, UCLA researchers have developed a low-cost, scalable method for building complex magnet arrays using a “discrete approximation” strategy. Instead of fabricating custom magnets, the method uses off-the-shelf cube magnets (like LEGO building blocks) that can be easily arranged in 3D-printed scaffolds. This process, called voxelization, breaks down complex magnet shapes into small cube elements that collectively mimic the behavior of the original design.
The approach enables rapid prototyping of advanced magnet arrays that would otherwise be too costly or impractical to build. For example, the team demonstrated a discretized version of a controllable Halbach array (D-CAHA) using 1,320 cube magnets and 3D-printed supports. This prototype achieved the same core functionality as an $11,500 custom-fabricated array at just 6% of the cost. In addition to cost savings, the method offers unique advantages: magnets can be reconfigured or recycled for new designs, arrays can be scaled or adjusted on demand, and novel geometries—like hollow or modular designs—become feasible for the first time.
By making complex magnet arrays accessible, safe, and affordable to prototype, this innovation enables faster design iteration in robotics, medical devices, prosthetics, and other mechatronic systems.
Advantages:
- Significant cost savings
- Rapid prototyping
- Reconfigurable & recyclable
- Safe & scalable
- Novel design flexibility and applicability to enable hollow, modular, or otherwise unmanufacturable magnet geometries
Potential Applications
- Robotic grippers for hazardous environments
- Magnetically controlled surgical instruments
- Wearable prosthetic attachment systems
- Compact, efficient motors for drones or vehicles
- Educational and research prototyping kits
- Adaptive industrial clamps and mounts
- Magnetic levitation platforms
Status of Development:
A discretized prototype has been successfully designed, built, and tested using cube magnets and 3D-printed scaffolds.
Related Publications:
- H. K. Lim, W. Flanagan, C. R. Taylor and T. R. Clites, "Discrete Approximation of Permanent Magnet Arrays for Mechatronic Applications," in IEEE/ASME Transactions on Mechatronics, doi: 10.1109/TMECH.2025.3620025.
- Flanagan, Will, et al. "Design of a controllable axial-flux Halbach array for magnetic suspension tasks." IEEE Access (2025)
Reference:
UCLA Case No. 2025-203
Lead Inventor:
Tyler Clites