Optimized electromagnetic inductor component design and methods including improved conductivity composite conductor material

A method of manufacturing an electromagnetic inductor component comprising:

• selecting a reference inductor component including a reference magnetic core and a reference conductor material and having a plurality of reference performance parameters selected from the group of at least an inductance value, an effective permeability, a saturation current value, and a direct current resistance value when connected to an electrical circuitry;
• providing a composite conductive material having a first conductivity greater than a second conductivity of the reference conductor material;
• determining a ratio of electrical conductivity (β) of the composite conductive material relative to the second conductivity of the reference conductor material;
• based on the determined ratio of electrical conductivity (β), determining an upper limit and lower limit of an effective diameter of the composite conductive material;
• and
• selecting a diameter within the determined upper and lower limit.