Fe-6.5Si-based Magnetic Cores with Metal-Insulator-Metal Structure via Dual-nozzle Material Extrusion (MEX) Technology

In this study, we proposed an innovative AM process for soft magnetic cores that integrated silicon steel sheets (high-silicon content) with SiO2 insulators. Utilizing a dual-nozzle MEX 3D printer, the process involved the fabrication of green parts from brittle Fe-6.5Si and SiO2, followed by the application of SPS to achieve high-density soft magnetic cores. The proposed method addresses the geometric limitations of traditional stamping processes and enhances energy efficiency by enabling a higher silicon content in the cores. Thus, it paves the way for more complex and efficient magnetic core designs for advanced applications.

本研究中，我们提出了一种创新的软磁芯AM工艺，该工艺将含硅量高的硅钢片与SiO2绝缘体相结合。利用双喷嘴的MEX 3D打印机，该工艺涉及从脆性Fe-6.5Si和SiO2材料中制备绿色零件，随后通过应用SPS技术以实现高密度软磁芯。所提出的方法克服了传统冲压工艺的几何限制，并通过允许在芯体中提高硅含量从而提升了能源效率。因此，为高级应用中的更复杂和高效的磁芯设计开辟了新的途径。