General Electric Company
Additive manufacturing-based low-profile inductor

Abstract:

A method of manufacturing an inductor core includes controlling a flow of magnetic material and a flow of binder material to a nozzle such that the flow magnetic material merges with the flow of binder material at a focal point of a preheater, preheating the magnetic material and the binder material by energizing the preheater, mixing the magnetic material and the binder material according to a ratio based on a magnetic permeability distribution of the inductor core, and depositing the magnetic material and the binder material on a surface to form the inductor core having three layers with recessed patterns defined between the layers for receiving a coil.