Additively manufactured high permeability Fe-Ni alloys and novel bi-metallic magnetic shields

•Multi-alloy, multi-layer shields were fabricated using blown powder directed energy deposition and showed a nearly 10 dB improvement in shielding performance compared single alloy shielding.•A mechanism relating the printing process parameters and microstructure to the soft magnetic performance of the material is proposed.•The directed energy deposited Fe-80Ni-5Mo alloy produced in this study possibly has the highest permeability and lowest coercivity of any AM soft magnetic alloy reported thus far.