Researchers at St. Thomas University in Minnesota recently used a FDM 3D printer to create a more efficient toroidal transformer core. The study has been published in the Journal of Magnetism and Magnetic Materials, entitled "3D Printing Magnetics." Polymer Composite Transformer ...
The iron core is the main magnetic circuit part of the transformer, and it forms a complete electromagnetic induction system with the coil wound around it. The amount of power transmitted by the transformer depends on the material and cross-sectional area of ​​the core.
In this study, the researchers sought to explore the use of 3D printing to create complex core shapes to increase their efficiency. In addition, researchers believe that the new transformer core manufacturing process may also reduce costs.
According to the study, “a ring-shaped geometry like a bagel theoretically maximizes the efficiency of the transformer because it shapes the closed magnetic flux.†However, due to manufacturing cost constraints, transformers tend to use a low The shape of efficiency. To change this situation, researchers can easily create complex shapes with 3D printing.
They used Proto-Pasta's "Rustable Magnetic Iron" wire, a PLA wire with iron injection, and a gCreate-gMax 3D printer to create a toroidal shape. The wire is extruded at 210 degrees Celsius and the composite PLA material provides magnetic elements.
The research paper concludes that the 3D printed core is indeed effective due to its shape. However, some other factors can optimize its magnetic properties. In particular, the researchers explained that if you want the 3D printed transformer iron to be most effective, you must have a high fill factor and a high concentration of magnetic particles.
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