University of Pittsburgh researchers have developed a novel method for producing ferrite-based soft magnetic cores using binder jet additive manufacturing combined with particle infiltration. These advanced materials are designed for high-frequency applications (>100kHz) and offer superior saturation flux densities compared to existing ferrites. This technology addresses the growing demand for higher power density electrical power conversion technologies in electric vehicles (EVs) and other electrified transportation systems.
Description
The invention utilizes binder jet additive manufacturing to create ferrite-based materials and ferrite nanocomposites capable of operating at high switching frequencies. The process involves binder jet printing, isothermal sintering, and particle infiltration to produce highly dense ferrites with arbitrary geometries and spatially tuned magnetic properties. This method allows for the fine-tuning of the chemistry and microstructure of the fabricated cores, resulting in improved performance and customizability. The technology enables the use of commercial ferrite powders and enhances manufacturing scalability while preserving the ability to customize magnetic properties.
Applications
• High-frequency power electronics (e.g., inductors, transformers)
• Electric vehicles (EVs) and electrified transportation systems
• Mobile on-board power electronics converters
• Off-board stationary fast chargers
Advantages
This technology offers several advantages, including the ability to produce ferrite cores with superior saturation flux densities and spatially tuned magnetic properties. The use of additive manufacturing allows for the creation of complex geometries and custom designs, improving performance and reducing size and weight. The process also enhances manufacturing scalability and enables the use of widely available commercial ferrite powders.
Invention Readiness
The invention is currently at the prototype stage, with successful demonstrations of its capabilities in producing high-density ferrite cores with improved magnetic properties. Further development and testing are ongoing to optimize the process and expand its applications in high-frequency power electronics.
IP Status
https://patents.google.com/patent/WO2025024532A1
