Recently, researchers at the University of St. Thomas in Minnesota used a FDM3D printer to make a more efficient donut-shaped transformer core. This research has been published in "JournalofMagnetismandMagneticMaterials", entitled "3D Printing Magnetic Polymer Composite Transformers" ".
The iron core is the main magnetic circuit part in the transformer, and it forms a complete electromagnetic induction system with the coil wound on it. Transformer power transmission depends on the core material and cross-sectional area.
In this study, the researchers aimed to explore the use of 3D printing to manufacture complex iron core shapes to improve their efficiency. In addition, the researchers believe that the new transformer core manufacturing process may also reduce costs.
According to this study, "a ring-shaped geometry like a donut theoretically maximizes the efficiency of the transformer, because such a shape maximizes the enclosed magnetic flux." However, due to manufacturing cost constraints, transformers often use a low Efficiency shape. To change this situation, the researchers used 3D printing to easily create complex shapes.
Core test: the left side is the winding core, and the right side is the core itself (a) commercial core (b) 3D printed core with the same shape as the commercial core (c) 3D printed ring core
They used Proto-Pasta's "Rustable Magnetic Iron (RustableMagneticIron)" wire-a PLA wire infused with iron, and a gCreate-gMax3D printer to create a ring shape. The wire is extruded at 210 degrees Celsius, and the composite PLA material provides the magnetic element.
The research paper concluded that because of its shape, 3D printed iron cores are indeed effective. However, some other factors can optimize its magnetic properties. The researchers specifically explained that for 3D printing transformer iron to be most effective, it must have a high fill factor and a high concentration of magnetic particles. 
Editor in charge: Liu Yang
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