Additive Manufacturing High Current Power Inductor

This study implemented an optimized 3-D power inductor design using the selective laser melting (SLM) method, which was developed for magnetic metal additive manufacturing. Traditional inductors often lack the optimization of the magnetic circuit, volume, and iron core air gap, resulting in larger sizes, easier magnetic saturation, and lower inductance value. In this work, the finite element analysis is employed to simulate and verify the 3-D design power inductance device. The SLM technology was integrated with oxygen control technology to mitigate the eddy current loss of the inductance. This combination allowed for the quick and accurate fabrication of the 3-D power inductance device without the need for mold making. By maintaining the original volume of the inductor and increasing the length of the magnetic circuit and the saturation magnetic flux, the maximum operating current was enhanced by about 20%. The experimental results with the prototype of the 3-D power inductance device are presented to validate the designed performance. Subsequently, these results are compared with the traditionally shaped inductances to assess the effectiveness of the optimized design.