{"id":{"repo_id":"uiuc","oai_identifier":"oai:www.ideals.illinois.edu:2142/102497"},"canonical_url":"https://search.dev.ndltd.org/etd/uiuc/oai:www.ideals.illinois.edu:2142/102497","repository":{"repo_id":"uiuc","name":"University of Illinois - Urbana-Champaign","base_url":"https://www.ideals.illinois.edu/oai-pmh"},"display":{"title":"Low temperature manufacturing of ferrite-epoxy inductor cores by micro-robotic deposition","abstract":"Inductors and transformers are an important class of passive components in high and pulsed power electronics. Inductive type elements such as these are useful in energy storage, pulse shaping or filtering, and power conversion. These devices are made up of two major components; the conductive windings that provide the inductive properties, and the magnetic cores used to enhance those properties. Power losses associated with these devices can also be categorized by these two components called copper and iron losses, respectively. Iron losses, or core losses, are highly dependent on the materials used and the manufacturing method for the core. Losses come in the form of thermal energy accumulated in the core itself. These devices, which can represent a plurality or even majority composition of power electronics circuitry, pose a significant challenge and opportunity to improve power density capabilities in high and pulsed power electronics. This thesis discusses manufacturing magnetic cores at low temperature (<100 C) and a control method for the manufacturing system. The manufacturing system of interest is micro-Robotic Deposition (uRD), a three-axis material extrusion type additive manufacturing system. The choice of this manufacturing method greatly influences the rheological properties required of the composite inks used for target components. A ferrite-epoxy composite ink consisting of micron-sized carbonyl iron powder and a common industrial epoxy matrix, Bisphenol-A diglycidyl ether (DGEBA)/ Diethylene Triamine (DETA), is used with a rheology modifier to achieve the proper rheology profile of the magnetic ink. A velocity centric PID control strategy is implemented on each axis of the uRD system to achieve proper motion and position control of the manufacturing process. Results show good control performance across printing speeds of 1-25 mm/s, as determined by biaxial contour mappings. Components manufactured from the composite provided hold the desired topology, indicating proper rheological tuning of the ink material, and were fully cured in under 8 hours at ambient room conditions (~23 C).","abstract_html":"Inductors and transformers are an important class of passive components in high and pulsed power electronics. Inductive type elements such as these are useful in energy storage, pulse shaping or filtering, and power conversion. These devices are made up of two major components; the conductive windings that provide the inductive properties, and the magnetic cores used to enhance those properties. Power losses associated with these devices can also be categorized by these two components called copper and iron losses, respectively. Iron losses, or core losses, are highly dependent on the materials used and the manufacturing method for the core. Losses come in the form of thermal energy accumulated in the core itself. These devices, which can represent a plurality or even majority composition of power electronics circuitry, pose a significant challenge and opportunity to improve power density capabilities in high and pulsed power electronics. This thesis discusses manufacturing magnetic cores at low temperature (&lt;100 C) and a control method for the manufacturing system. The manufacturing system of interest is micro-Robotic Deposition (uRD), a three-axis material extrusion type additive manufacturing system. The choice of this manufacturing method greatly influences the rheological properties required of the composite inks used for target components. A ferrite-epoxy composite ink consisting of micron-sized carbonyl iron powder and a common industrial epoxy matrix, Bisphenol-A diglycidyl ether (DGEBA)/ Diethylene Triamine (DETA), is used with a rheology modifier to achieve the proper rheology profile of the magnetic ink. A velocity centric PID control strategy is implemented on each axis of the uRD system to achieve proper motion and position control of the manufacturing process. Results show good control performance across printing speeds of 1-25 mm/s, as determined by biaxial contour mappings. Components manufactured from the composite provided hold the desired topology, indicating proper rheological tuning of the ink material, and were fully cured in under 8 hours at ambient room conditions (~23 C).","abstract_has_math":false,"creators":["Igram, Spencer Scott"],"institution":"University of Illinois at Urbana-Champaign","degree_name":"M.S.","degree_level":"Thesis","degree_discipline":"Mechanical Engineering","degree_department":null,"school":null,"contributors":["Alleyne, Andrew"],"advisors":[],"committee_chairs":[],"committee_members":[],"year":2019,"date_issued":"2019-02-06T19:36:40Z","date_published":"2019-02-06T19:36:40Z","updated_at":"2026-07-22T22:24:42Z","subjects":["Ferrite","Additive Manufacturing","Epoxy Composite","Ferromagnetic","Inductor","Magnetic Core","Manufacturing","Material Extrusion","Direct Ink Write","DIW","3D printing"],"languages":["en"],"rights":["Copyright 2018 Spencer Igram"],"rights_urls":[],"identifier_entries":[]},"links":{"outbound_url":"http://hdl.handle.net/2142/102497","outbound_label":"Handle","outbound_source":"dc:identifier"},"metadata_groups":[{"id":"people","label":"People","entries":[{"key":"dc:contributor","label":"Contributor","values":["Alleyne, Andrew"]},{"key":"dc:creator","label":"Author","values":["Igram, Spencer Scott"]}]},{"id":"academic_context","label":"Academic Context","entries":[{"key":"dc:date","label":"Dc Date","values":["2019-02-06T19:36:40Z","2018-12-11","2018-12"]},{"key":"dc:type","label":"Dc Type","values":["text"]},{"key":"thesis:degree_discipline","label":"Discipline","values":["Mechanical Engineering"]},{"key":"thesis:degree_level","label":"Degree Level","values":["Thesis"]},{"key":"thesis:degree_name","label":"Degree Name","values":["M.S."]},{"key":"thesis:institution_name","label":"Thesis Institution Name","values":["University of Illinois at Urbana-Champaign"]}]},{"id":"subjects_keywords","label":"Subjects and Keywords","entries":[{"key":"dc:subject","label":"Dc Subject","values":["Ferrite","Additive Manufacturing","Epoxy Composite","Ferromagnetic","Inductor","Magnetic Core","Manufacturing","Material Extrusion","Direct Ink Write","DIW","3D printing"]}]},{"id":"language_rights","label":"Language and Rights","entries":[{"key":"dc:language","label":"Dc Language","values":["en"]},{"key":"dc:rights","label":"Dc Rights","values":["Copyright 2018 Spencer Igram"]}]},{"id":"identifiers","label":"Identifiers","entries":[{"key":"dc:identifier","label":"Identifier","values":["http://hdl.handle.net/2142/102497"]}]},{"id":"additional","label":"Additional Metadata","entries":[{"key":"dc:description","label":"Description","values":["Inductors and transformers are an important class of passive components in high and pulsed power electronics. Inductive type elements such as these are useful in energy storage, pulse shaping or filtering, and power conversion. These devices are made up of two major components; the conductive windings that provide the inductive properties, and the magnetic cores used to enhance those properties. Power losses associated with these devices can also be categorized by these two components called copper and iron losses, respectively. Iron losses, or core losses, are highly dependent on the materials used and the manufacturing method for the core. Losses come in the form of thermal energy accumulated in the core itself. These devices, which can represent a plurality or even majority composition of power electronics circuitry, pose a significant challenge and opportunity to improve power density capabilities in high and pulsed power electronics. This thesis discusses manufacturing magnetic cores at low temperature (<100 C) and a control method for the manufacturing system. The manufacturing system of interest is micro-Robotic Deposition (uRD), a three-axis material extrusion type additive manufacturing system. The choice of this manufacturing method greatly influences the rheological properties required of the composite inks used for target components. A ferrite-epoxy composite ink consisting of micron-sized carbonyl iron powder and a common industrial epoxy matrix, Bisphenol-A diglycidyl ether (DGEBA)/ Diethylene Triamine (DETA), is used with a rheology modifier to achieve the proper rheology profile of the magnetic ink. A velocity centric PID control strategy is implemented on each axis of the uRD system to achieve proper motion and position control of the manufacturing process. Results show good control performance across printing speeds of 1-25 mm/s, as determined by biaxial contour mappings. Components manufactured from the composite provided hold the desired topology, indicating proper rheological tuning of the ink material, and were fully cured in under 8 hours at ambient room conditions (~23 C).","Submission original under an indefinite embargo labeled 'Open Access'. The submission was exported from vireo on 2019-02-05 without embargo terms","The student, Spencer Igram, accepted the attached license on 2018-12-07 at 10:27.","The student, Spencer Igram, submitted this Thesis for approval on 2018-12-07 at 10:35.","This Thesis was approved for publication on 2018-12-11 at 15:37.","DSpace SAF Submission Ingestion Package generated from Vireo submission #13251 on 2019-02-05 at 11:15:47","Made available in DSpace on 2019-02-06T19:36:40Z (GMT). No. of bitstreams: 2 IGRAM-THESIS-2018.pdf: 3100511 bytes, checksum: b1216ee8ed6280dfe39194ae699ab17d (MD5) LICENSE.txt: 4210 bytes, checksum: 6765312530d735641bf878b6f34a0834 (MD5) Previous issue date: 2018-12-11"]},{"key":"dc:format","label":"Dc Format","values":["application/pdf"]},{"key":"dc:title","label":"Title","values":["Low temperature manufacturing of ferrite-epoxy inductor cores by micro-robotic deposition"]}]}],"canonical_facts":{"dc:contributor":["Alleyne, Andrew"],"dc:creator":["Igram, Spencer Scott"],"dc:date":["2019-02-06T19:36:40Z","2018-12-11","2018-12"],"dc:description":["Inductors and transformers are an important class of passive components in high and pulsed power electronics. Inductive type elements such as these are useful in energy storage, pulse shaping or filtering, and power conversion. These devices are made up of two major components; the conductive windings that provide the inductive properties, and the magnetic cores used to enhance those properties. Power losses associated with these devices can also be categorized by these two components called copper and iron losses, respectively. Iron losses, or core losses, are highly dependent on the materials used and the manufacturing method for the core. Losses come in the form of thermal energy accumulated in the core itself. These devices, which can represent a plurality or even majority composition of power electronics circuitry, pose a significant challenge and opportunity to improve power density capabilities in high and pulsed power electronics. This thesis discusses manufacturing magnetic cores at low temperature (<100 C) and a control method for the manufacturing system. The manufacturing system of interest is micro-Robotic Deposition (uRD), a three-axis material extrusion type additive manufacturing system. The choice of this manufacturing method greatly influences the rheological properties required of the composite inks used for target components. A ferrite-epoxy composite ink consisting of micron-sized carbonyl iron powder and a common industrial epoxy matrix, Bisphenol-A diglycidyl ether (DGEBA)/ Diethylene Triamine (DETA), is used with a rheology modifier to achieve the proper rheology profile of the magnetic ink. A velocity centric PID control strategy is implemented on each axis of the uRD system to achieve proper motion and position control of the manufacturing process. Results show good control performance across printing speeds of 1-25 mm/s, as determined by biaxial contour mappings. Components manufactured from the composite provided hold the desired topology, indicating proper rheological tuning of the ink material, and were fully cured in under 8 hours at ambient room conditions (~23 C).","Submission original under an indefinite embargo labeled 'Open Access'. The submission was exported from vireo on 2019-02-05 without embargo terms","The student, Spencer Igram, accepted the attached license on 2018-12-07 at 10:27.","The student, Spencer Igram, submitted this Thesis for approval on 2018-12-07 at 10:35.","This Thesis was approved for publication on 2018-12-11 at 15:37.","DSpace SAF Submission Ingestion Package generated from Vireo submission #13251 on 2019-02-05 at 11:15:47","Made available in DSpace on 2019-02-06T19:36:40Z (GMT). No. of bitstreams: 2 IGRAM-THESIS-2018.pdf: 3100511 bytes, checksum: b1216ee8ed6280dfe39194ae699ab17d (MD5) LICENSE.txt: 4210 bytes, checksum: 6765312530d735641bf878b6f34a0834 (MD5) Previous issue date: 2018-12-11"],"dc:format":["application/pdf"],"dc:identifier":["http://hdl.handle.net/2142/102497"],"dc:language":["en"],"dc:rights":["Copyright 2018 Spencer Igram"],"dc:subject":["Ferrite","Additive Manufacturing","Epoxy Composite","Ferromagnetic","Inductor","Magnetic Core","Manufacturing","Material Extrusion","Direct Ink Write","DIW","3D printing"],"dc:title":["Low temperature manufacturing of ferrite-epoxy inductor cores by micro-robotic deposition"],"dc:type":["text"],"thesis:degree_discipline":["Mechanical Engineering"],"thesis:degree_level":["Thesis"],"thesis:degree_name":["M.S."],"thesis:institution_name":["University of Illinois at Urbana-Champaign"]},"updated_at":"2026-07-22T22:24:42Z"}