Abstract
Additive manufacturing (AM) has the potential to rapidly prototype innovative designs of magnetic components aimed at improving power density and efficiency of switch-mode power converters. However, only a few magnetic feedstocks are available for AM, and the fabricated parts have significantly poorer magnetic properties. Our previous studies showed the promise of an extrusion-based AM platform for making high-performance power magnetics. But, the magnetic paste feedstock developed in these studies suffered from the “slumping” problem, thus not suitable for building large or tall core structures. To improve the AM capability, a ferrite paste was developed that is cured upon ultraviolet (UV) illumination. Core structures with large aspect ratios were fabricated by retrofitting the printer with a UV-light-emitting diode module. By varying the magnetic composition of the paste and sintering the printed parts at and below 1000 °C, we made tall (>4 mm) ferrite cores with relative permeability ranging from 63 to 103 and resonance frequency higher than 30 MHz.
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