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.