A core with 65% powder equipped with a solenoid made out of 25 µm thick insulated Au wire having 30 turns, yielded a constant inductance value of 2 µH up to the frequency of 50 MHz and a peak quality factor of 13. Inductor chips having a solenoidal coil as well as transformer chips with primary and secondary coils wound around each other have been fabricated and evaluated. The core influence on the electrical performance of the inductive elements is discussed. Cylindrical PMC cores having a footprint of 0.79 mm 2 were fabricated with varying percentage of the magnetic powder on FR4 substrates. High permeability NiFeZn powder was mixed with Araldite epoxy to form high resistive PMC cores. An optimized fabrication process of molding, casting, and demolding which uses teflon for the molding tool is presented. The new PMC cores provide a possibility to bridge the gap between the non-magnetic and magnetic core inductive devices in terms of both the operating frequency and electrical performance. We present a rapid prototyping and a cost effective fabrication process on batch fabricated wafer-level micro inductive components with polymer magnetic composite (PMC) cores.
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