Soft magnetic composites (SMCs) are valuable materials due to their impressive magnetic properties and the ability to be formed into different shapes. The aim of this research is to investigate the influence of the ball to powder ratio (BPR) and innovative method of powder surface treatment on the magnetic performance of SMCs. Six samples were prepared using planetary ball mill with varying BPR values and inorganic insulation. Magnetic properties were evaluated using hysteresis loop, and initial magnetization curve measurements. The study revealed a clear correlation between increased BPR value and higher maximum magnetization for samples without surface treatment. Additionally, a positive correlation was observed between the consistency of the insulation layer and the implementation of powder surface treatment. However, high SiO₂ content in some samples negatively impacted their magnetic properties due to its non-ferromagnetic nature and the insulating SiO₂ formed during processing. Surface treatment and an optimal ball milling ratio (BPR) significantly enhance the soft magnetic properties of ferromagnetic materials. A BPR of 3:1 with surface treatment yielded the best magnetic performance, while higher BPRs (9:1) improved magnetic properties by reducing particle size, despite introducing structural defects. Silicon content in samples reduced magnetic properties due to its non-ferromagnetic nature and insulating silica formation.

Acknowledgement: This research was supported by the Scientific Grant Agency of the Ministry of Education of Slovak Republic and the Slovak Academy of Science (grant numbers VEGA 1/0403/23 and KEGA 006TUKE-4/2025) and by Ulysseus: Seed Fund Call for Teachers. Collaborative Online International Learning (COIL), 2024-2025.