Patent ID: 7596856

Claim:
A method for manufacturing a soft magnetic metal electromagnetic component comprising the steps of: forming soft magnetic metal ribbon having edges into a pre-form comprising a plurality of stacked or wound layers of the ribbon, the edges being in registry and the ribbon consisting essentially of a material selected from the group consisting of amorphous and nanocrystalline metals and optimized Fe-based alloy; containing the pre-form within a containment means that supports the pre-form on all sides; milling the pre-form contained within the containment means into a electromagnetic component shape; and thermally processing the electromagnetic component shape into an electromagnetic component at a thermal processing temperature, and wherein the containing step comprises the steps of applying an adhesive to the pre-form; and curing the adhesive to form a bonded pre-form, the curing being carried out at a heat curing temperature less than the thermal processing temperature.