High Density Bi-Directional Modular Power Converter with Additive Manufactured Magnetics

SET group proposes the High Density Bi-Directional Modular Power Converter with Additive Manufactured Magnetics as a solution to NASArsquo;s interest for high power density/efficiency, modular electrical systems. The proposed design will be able to function as a bus and battery charge/discharge regulator and as a bus powernbsp;converter. This will allow the proposed unit to perform multiple functions, aligning with NASArsquo;s AMPS goal for power system modularity and interoperability. SET group will leverage Direct Metal Laser Sintering (DMLS) Advanced Manufacturing (AM) techniques and equipment to design and fabricate magnetic composite electromagnetic cores that will replace traditional electromagnetic onboard components. SET grouprsquo;s technical team has expertise and know-how in AM engineering, processes, and production. SET group has previously pushed the limits of AM and successfully designed and fabricated AM enclosures and 2-phase thermal management devices using copper and aluminum. This proposal will push the boundaries of AM methods and technology to produce low SWaP-C magnetic composites.SET grouprsquo;s proposed design integrates space-grade GaN HEMTs and AM for the fabrication of magnetic components. Conventional machining capabilities limits electromagnetic engineers to primitive core sizes and shapes that are standard offerings by a limited number of distributers. When a design necessitates a custom core size, machining such cores has a considerable lead time and production risks which yields project delays and increased costs. The more complex a transformer core is, the more difficult it is to ensure quality and reliability as the processing variabilities stack-up through the production process. Our proposed design will make use of AM which will unlock the production of cost-effective and geometrically unconstrained magnetic designs that will lead to a smaller form factor, faster production, and higher efficiency with increased reliability and lot-to-lot quality