Additive manufacturing of Fe-6.5Si cores with metal-insulator-metal structure via dual-nozzle material extrusion (MEX) technology
This study proposes a novel approach for fabricating Fe-6.5 wt. %Si (Fe-6.5Si) soft magnetic cores using a dual-nozzle material extrusion (MEX) three-dimensional (3D) printing technology followed by a spark plasma sintering (SPS) process. A SiO2 insulator was printed between the Fe-6.5Si layers to f...
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Taylor & Francis Group
2025-12-01
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| Series: | Virtual and Physical Prototyping |
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| Online Access: | https://www.tandfonline.com/doi/10.1080/17452759.2025.2457027 |
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| author | Taehyeob Im Suyeon Kim Juyong Kim Minjong Kim Jonghyeok Ahn Kwiyoung Lee Dongju Lee Jai-Sung Lee Jongryoul Kim Caroline Sunyong Lee |
| author_facet | Taehyeob Im Suyeon Kim Juyong Kim Minjong Kim Jonghyeok Ahn Kwiyoung Lee Dongju Lee Jai-Sung Lee Jongryoul Kim Caroline Sunyong Lee |
| author_sort | Taehyeob Im |
| collection | DOAJ |
| description | This study proposes a novel approach for fabricating Fe-6.5 wt. %Si (Fe-6.5Si) soft magnetic cores using a dual-nozzle material extrusion (MEX) three-dimensional (3D) printing technology followed by a spark plasma sintering (SPS) process. A SiO2 insulator was printed between the Fe-6.5Si layers to fabricate metal–insulator-metal (MIM)-structured cores. Densified Fe-6.5Si soft magnetic cores (over 99%) were obtained owing to the resolution of the sintering problem with Fe-6.5Si because of its brittle nature using SPS. The magnetic core with a 0.2 mm-printed insulator (MC0.2) achieved a uniform insulator thickness of approximately 85 µm. Despite MC0.2 being approximately three times thicker than the single Fe-6.5Si layer (magnetic core single layer, MCS), a SiO2 insulator used in the cores of MC0.2 and MCS, resulted in comparable eddy current losses at 1 kHz. This highlighted the effectiveness of the MIM structure in suppressing the eddy currents. Thus, the proposed approach offers a promising solution for overcoming the geometric limitations of traditional stamping processes and paves the way for advanced magnetic core applications in additive manufacturing. |
| format | Article |
| id | doaj-art-91d2a7f0f86643a6a74561a626e392fb |
| institution | Kabale University |
| issn | 1745-2759 1745-2767 |
| language | English |
| publishDate | 2025-12-01 |
| publisher | Taylor & Francis Group |
| record_format | Article |
| series | Virtual and Physical Prototyping |
| spelling | doaj-art-91d2a7f0f86643a6a74561a626e392fb2025-01-29T21:01:20ZengTaylor & Francis GroupVirtual and Physical Prototyping1745-27591745-27672025-12-0120110.1080/17452759.2025.2457027Additive manufacturing of Fe-6.5Si cores with metal-insulator-metal structure via dual-nozzle material extrusion (MEX) technologyTaehyeob Im0Suyeon Kim1Juyong Kim2Minjong Kim3Jonghyeok Ahn4Kwiyoung Lee5Dongju Lee6Jai-Sung Lee7Jongryoul Kim8Caroline Sunyong Lee9Department of Materials and Chemical Engineering, Hanyang University ERICA, Ansan, Republic of KoreaDepartment of Advanced Materials Engineering, Chungbuk National University, Cheongju, Republic of KoreaReprotech 3DP R&D Center, Yongin, Republic of KoreaReprotech 3DP R&D Center, Yongin, Republic of KoreaDepartment of Materials and Chemical Engineering, Hanyang University ERICA, Ansan, Republic of KoreaDepartment of Materials and Chemical Engineering, Hanyang University ERICA, Ansan, Republic of KoreaDepartment of Advanced Materials Engineering, Chungbuk National University, Cheongju, Republic of KoreaDepartment of Materials and Chemical Engineering, Hanyang University ERICA, Ansan, Republic of KoreaDepartment of Materials and Chemical Engineering, Hanyang University ERICA, Ansan, Republic of KoreaDepartment of Materials and Chemical Engineering, Hanyang University ERICA, Ansan, Republic of KoreaThis study proposes a novel approach for fabricating Fe-6.5 wt. %Si (Fe-6.5Si) soft magnetic cores using a dual-nozzle material extrusion (MEX) three-dimensional (3D) printing technology followed by a spark plasma sintering (SPS) process. A SiO2 insulator was printed between the Fe-6.5Si layers to fabricate metal–insulator-metal (MIM)-structured cores. Densified Fe-6.5Si soft magnetic cores (over 99%) were obtained owing to the resolution of the sintering problem with Fe-6.5Si because of its brittle nature using SPS. The magnetic core with a 0.2 mm-printed insulator (MC0.2) achieved a uniform insulator thickness of approximately 85 µm. Despite MC0.2 being approximately three times thicker than the single Fe-6.5Si layer (magnetic core single layer, MCS), a SiO2 insulator used in the cores of MC0.2 and MCS, resulted in comparable eddy current losses at 1 kHz. This highlighted the effectiveness of the MIM structure in suppressing the eddy currents. Thus, the proposed approach offers a promising solution for overcoming the geometric limitations of traditional stamping processes and paves the way for advanced magnetic core applications in additive manufacturing.https://www.tandfonline.com/doi/10.1080/17452759.2025.2457027Fe-6.5Si soft magnetic coresdual-nozzle MEX 3D printingspark plasma sinteringmetal-insulator-metal structurecore loss |
| spellingShingle | Taehyeob Im Suyeon Kim Juyong Kim Minjong Kim Jonghyeok Ahn Kwiyoung Lee Dongju Lee Jai-Sung Lee Jongryoul Kim Caroline Sunyong Lee Additive manufacturing of Fe-6.5Si cores with metal-insulator-metal structure via dual-nozzle material extrusion (MEX) technology Virtual and Physical Prototyping Fe-6.5Si soft magnetic cores dual-nozzle MEX 3D printing spark plasma sintering metal-insulator-metal structure core loss |
| title | Additive manufacturing of Fe-6.5Si cores with metal-insulator-metal structure via dual-nozzle material extrusion (MEX) technology |
| title_full | Additive manufacturing of Fe-6.5Si cores with metal-insulator-metal structure via dual-nozzle material extrusion (MEX) technology |
| title_fullStr | Additive manufacturing of Fe-6.5Si cores with metal-insulator-metal structure via dual-nozzle material extrusion (MEX) technology |
| title_full_unstemmed | Additive manufacturing of Fe-6.5Si cores with metal-insulator-metal structure via dual-nozzle material extrusion (MEX) technology |
| title_short | Additive manufacturing of Fe-6.5Si cores with metal-insulator-metal structure via dual-nozzle material extrusion (MEX) technology |
| title_sort | additive manufacturing of fe 6 5si cores with metal insulator metal structure via dual nozzle material extrusion mex technology |
| topic | Fe-6.5Si soft magnetic cores dual-nozzle MEX 3D printing spark plasma sintering metal-insulator-metal structure core loss |
| url | https://www.tandfonline.com/doi/10.1080/17452759.2025.2457027 |
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