System and method for making a structured magnetic material with integrated particle insulation

1. A method of forming a soft magnetic bulk material of a predetermined shape from a magnetic material and a source of insulating material, the method comprising:

providing a heating device;

providing a deposition device;

providing a support configured to support the soft magnetic bulk material of the predetermined shape;

providing a mask subsystem configured as a negative of at least a portion of the predetermined shape;

heating the magnetic material with the heating device to form particles having a softened state;

locating the mask subsystem between the deposition device and the support;

depositing successive layers of particles of the magnetic material in the softened state with the deposition device on the support; and

indexing, to a position relative to the support, the mask subsystem upon deposition of the successive layers;

wherein the mask subsystem selectively blocks the successive layers of particles of the magnetic material in the softened state from being deposited on the support thus forming the soft magnetic bulk material of a predetermined shape on the support.

2. The method of claim 1 wherein the mask subsystem comprises a first and second mask.

3. The system of claim 1 wherein the mask subsystem comprises a first and second mask and wherein the first mask is moveable relative to the second mask.

4. The method of claim 1 wherein the soft magnetic bulk material of a predetermined shape has a uniform cross section.

5. The method of claim 1 wherein the soft magnetic bulk material of a predetermined shape has a non-uniform cross section.

6. The method of claim 1 wherein the mask subsystem comprises more than one mask having different shapes corresponding to different cross sections of the soft magnetic bulk material of a predetermined shape with a non-uniform cross section at different index positions.

7. A method of forming a soft magnetic bulk material of a predetermined shape from a magnetic material and a non-magnetic material, the method comprising:

providing a reservoir adapted to contain the soft magnetic bulk material of the predetermined shape;

providing a heat source; and

heating the magnetic material and the non-magnetic material in the reservoir to an ignition temperature of a reaction thus forming the soft magnetic bulk material of a predetermined shape;

wherein the soft magnetic bulk material of a predetermined shape has domains formed from the magnetic material with insulating boundaries formed from the reaction.

8. The method of claim 7 wherein the reservoir comprises a movable support.

9. The method of claim 7 wherein the heat source comprises a laser.

10. The method of claim 7 wherein the reaction comprises a thermite reaction.

11. The method of claim 7 wherein the domains comprise iron and wherein the insulating material comprises aluminum oxide.

12. The method of claim 7 wherein the reaction comprises a thermite reaction and wherein the magnetic material comprises coated iron particles and wherein the non magnetic material comprises aluminum.

13. The method of claim 7 wherein forming the soft magnetic bulk material of a predetermined shape comprises an additive process.

14. The method of claim 7 wherein the reservoir comprises a mold.