3D structure design of magnetic ferrite cores using gelcasting and pressure-less sintering process

Gelcasting is a well established process for ceramics manufacturing which recently has been proved to be successful for soft ferrites as well. This approach is particularly interesting for power electronics application in which the magnetic components (e.g. transformers and inductors) are three dimensionally integrated on the power module substrate. This paper proposes a gelcasting process adapted to make it more effective for 3D heterogeneous integration. The main novelties in this direction consist of low solid load (65wt%) and gelation without catalyst to improve casting and de-airing steps. The magnetic properties of gelcast samples are compared with commercial materials and correlated with the microstructure.