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Eddy Current Loss Reduction Prospects in Laser Additively Manufactured Soft Magnetic Cores

The past decade has seen the development of additive manufacturing (AM) of functional electromagnetic components into a promising new area of research. The combination of previously unseen rapid prototyping capacity, coupled with its unparalleled design freedom, is bound to yield novel, previously unfeasible component designs. Several challenges remain, however, in printing soft magnetic flux guides: most prominently, how to achieve competitive iron losses within printed cores? This manuscript investigates possibilities of eddy current loss reduction in AM soft magnetic cores. Current strategies are discussed, hypothetical possibilities explored, and the state-of-the-art demonstrated with empirical measurements.