Additive Manufacturing Lightweight Inductor

This study is predicated upon the utilization of an original shaped inductor, centering on the innovation of a three-dimensional inductor design as its foundational element. A novel three-dimensional trench inductor has been developed, maintaining consistency in switching frequency and material selection. Enhancements in winding and volume have been achieved through the incorporation of the trench. A distinctive feature of this design is the capability to embed wiring directly within the inductor, thereby diminishing the requisite amount of copper wire and core weight. The influence of the trench on the magnetic circuit is examined through electromagnetic simulation, facilitating the geometric design and validation of high-frequency inductors. Conclusively, this research employs 3D-printed iron cores in converter circuits to corroborate the efficacy of this design in reducing both copper and core weight.