High-frequency core loss (
Pcv) constitutes a critical bottleneck restricting the widespread application of soft magnetic composites (SMCs) in next-generation, high-frequency, miniaturized power electronic systems. To effectively suppress such losses, the synergistic optimization of insulating coatings and processing parameters represents a core strategic approach. In this work, Fe
73.5Si
13.5B
9Nb
3Cu
1 nanocrystalline powders with a mean particle size of 12.98 μm are employed as the magnetic matrix. A series of SMC toroidal cores with varying epoxy resin (EP) coating contents is then fabricated through a sequential process of powder insulation, uniaxial compaction at 1800 MPa, and subsequent stress-relief annealing at 450 ℃. The effect of EP coating content on the insulation integrity and high-frequency magnetic performance of SMCs is systematically investigated. At an optimal content of 2 wt.% (designated as EP2), the
Pcv is significantly reduced, yielding values of 628 mW/cm
3 at 20 mT/1000 kHz and 283 mW/cm
3 at 50 mT/100 kHz. These loss characteristics are superior to those of most reported SMCs under equivalent testing conditions. Bertotti loss separation reveals that increasing the EP coating content slightly reduces eddy-current loss (
Pe) while substantially increasing hysteresis loss (
Ph). Specifically, upon increasing the EP content from 2 wt.% to 3 wt.%, the contribution of
Pe to
Pcv decreases from 60% to 48%, whereas that of
Ph increases from 40% to 52%. This indicates a transition of the dominant loss mechanism from
Pe to
Ph, with the rising proportion of the latter being the primary cause for the overall increase in
Pcv. The proper EP coating content reduces porosity and enhances the densification of the magnetic powder core. Meanwhile, it forms a uniform, continuous, and dense coating layer that effectively suppresses localized agglomeration between particles. This combined effect enables the EP2 sample to achieve an optimal balance between
Ph and
Pe, thereby yielding the minimum
Pcv. Through precise control of the EP coating content, synergistic regulation of individual loss components can be realized without resorting to complex strategies such as multi-layer coating or interfacial modification. This approach thus provides an effective and straightforward pathway for loss management in high-frequency, high-power magnetic components.