This study investigates the challenges of additively manufactured interlocking structures, emphasizing joinability issues due to thermal deformation. These challenges become pronounced when fabricating high-density structures without fully interconnected layers, a trait common in soft magnetic materials. Here, a detailed analysis assessing deformation concerning pin thickness and build orientation in a representative interlocking model is performed. Utilizing stress and thermal simulations of the additive manufacturing process, it is shown that a compensated design considerably enhances the joinability of these structures. These findings offer valuable perspectives for advancing the design of additive manufacturing components, particularly in soft magnetic materials such as electric motor stators, which require both insulation and density.
