3-dimensional printing process for integrated magnetics

A method of forming a device with an integrated magnetic component using three-dimensional printing, the method comprising:

• providing a substrate with a first dielectric layer;
• forming a first layer of a metal winding on the first dielectric layer by spray coating a metal powder over the first dielectric layer and selective laser sintering the metal powder;
• forming a second dielectric layer over the first layer of the metal winding and the first dielectric layer;
• patterning the second dielectric layer to include a first plurality of openings extending to the first layer of the metal winding;
• forming a magnetic core on the second dielectric layer by spray coating a magnetic powder over the second dielectric layer and selective laser sintering the magnetic powder;
• forming a third dielectric layer over the magnetic core and the second dielectric layer;
• patterning the third dielectric layer to include a second plurality of openings connected with the first plurality of openings;
• and
• forming a second layer of the metal winding on the third dielectric layer by spray coating a metal powder over the substrate and selective laser sintering the metal powder,
• wherein the second dielectric layer and the third dielectric layer insulate the first and second layers of the metal winding from the magnetic core, and the spray coating of the metal powder of the second layer of the metal winding fills the first plurality of openings and the second plurality of openings such that, after selective layer sintering, the first and second layers of the metal winding are interconnected and surround the magnetic core.