Hi Ford,
Ferrite is a ceramic material. The process begins with a
multi-hundred ton press for large parts. The pressed form is then
fired much like pottery.
The state of the art using very large press's produces single-piece
units with dimensions of only few inches at most. Large pieces are
fabricated from an assembly of smaller pieces. There are companies
like Ceramic Magnetic who do this but hang on to your wallet.
Huge assemblies have been done successfully. For example the
transductors used for tuning VLF antennas like Jim Creek used cores
built up from ferrite bricks back in the 50's. The core dimensions
were in feet!
73, Rudy N6LF
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