Additive manufacturing of shaped profile windings for minimal AC loss in gapped inductors

Wound components typically represent approximately 50 % of the total mass of a power converter, consequently minimising the mass and volume of transformers and filter inductors is an important challenge in the design of compact power dense converters in transport and other demanding applications. The research described in this paper contributes to a body of work investigating design tools and new manufacturing processes aimed at reducing the mass and volume of wound components. In this instance, the design and manufacture of minimal AC loss shaped profile windings using metal additive manufacturing is explored. A prototype inductor is manufactured and experimentally tested to demonstrate the advantages of shaped windings for AC loss reduction.