Binder Jet Printed Ferrite Cores and Lithographically Printed Ceramic Bobbins for Power Conversion

Abstract

Magnetics such as transformers and inductors, and capacitors have become limiting factors in increasing power density. They are limited by conventional manufacturing techniques in shapes and sizes, and in harsh environments, they often become the thermally limiting components in a converter. This paper focuses on additive methods for printing unconventional shapes in magnetics that can enable higher power density, and the printing of ceramic bobbins that can extract heat from the interior of a magnetic while enhancing dielectric strength. Cores printed with binder jet printing and lithography based ceramic printing of bobbins are experimentally demonstrated. Test results are presented with challenges and future advancements.