This article presents a timely report on 3D printed cobalt iron (CoFe) soft magnetic cores enabled by the latest advances of additive manufacturing technologies. The feasibility of 3D printing CoFe magnetic cores is demonstrated in a current-ripple-filtering line inductor for power electronics applications. A like-for-like comparison is conducted between the 3D printed solid core and a commercial laminated core with the identical outer geometries to benchmark the former. Performance of the cores is evaluated based on assembled inductors regarding two key high-frequency characteristics, the inductance and the core losses. The results show that the effective permeability of the 3D printed core reduces rapidly with the increase of frequency, due to the low effective resistivity and consequently prominent eddy currents. When the functional equivalent is achieved, i.e., the same inductance for filtering switching-frequency current ripples, the inductor with 3D printed CoFe cores shows five times larger core losses compared with the commercial laminated core.

中文翻译：

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用于滤波器电感器的 3D 打印钴铁芯的评估

本文及时报告了由增材制造技术的最新进展实现的 3D 打印钴铁 (CoFe) 软磁芯。用于电力电子应用的电流纹波滤波线路电感器证明了 3D 打印 CoFe 磁芯的可行性。在 3D 打印的实心铁芯和具有相同外部几何形状的商用叠片铁芯之间进行了同类比较，以对前者进行基准测试。磁芯的性能基于组装电感器的两个关键高频特性（电感和磁芯损耗）进行评估。结果表明，由于低有效电阻率和显着的涡流，3D 打印芯的有效磁导率随着频率的增加而迅速降低。