3D printed high frequency inductor for electric vehicles for both higher efficiency and higher power density

Important results from the project

The purpose of the project was to evaluate a 3D printed inductor with amorphous / nanocrystalline solid core, with the aim of producing an inductor intended for high frequencies but with low electrical losses. The target value for permeability was not reached but could still be used for an inductor, however, the losses were high mainly due to eddy current. Furthermore, a measuring fixture was developed to be able to measure resistivity on short cylinders. The project also contributed to determine electrical, thermal and magnetic properties for Exmet´s first commercial product.

Expected long term effects

In this study, a 3D-printed amorphous / nanocrystalline solid core was evaluated. The target value for permeability was not reached but could still be used for an inductor. A measuring fixture was also developed to be able to measure resistivity on short cylinders. The project also contributed to determine electrical, thermal and magnetic material data for Exmet´s first commercial product.

Approach and implementation

The project was a feasibility study, and with the relatively limited budget, a great deal of information and insights were gained. The composition of the project group was very good. The combination of Inmotion´s need for improved performance of inductor and transformer and Hans Peter Nee from KTH, expert knowledge resulted in an effective exchange of knowledge. Everyone in the project agreed that the project generated knowledge and experiences that no one would want to be without. Exmet contributed to an active discussion during the project with other project participants.