Fuel injector and method of manufacturing the same

A fuel injector, comprising:

• a tubular casing defining an axial fuel passage;
• a valve seat element disposed within said axial fuel passage, said valve seat element defining a fuel outlet communicated with said axial fuel passage;
• a valve element axially moveable within said axial fuel passage between an open position where said valve element is out of contact with said valve seat element to allow fluid communication between said axial fuel passage and said fuel outlet and a closed position where said valve element is in contact with said valve seat element to block the fluid communication;
• a core cylinder axially opposed to said valve element with an axial air gap;
• a spring biasing said valve element toward the closed position, said spring being disposed within said axial fuel passage;
• and
• an electromagnetic actuator cooperating with said casing, said valve element and said core cylinder to form a magnetic field forcing said valve element to the open position against said spring upon being energized,
• said casing being formed with a reluctance portion producing an increased magnetic reluctance and allowing the magnetic field to pass through the axial air gap between said valve element and said core cylinder, said reluctance portion having a reduced radial thickness and an axial length extending over the axial air gap.