Generative AI for 3D Printed Antenna Design
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Chavez, Jennifer Ann [Sandia National Laboratories↗
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Ultra-light antennas via charge programmed deposition additive manufacturing
Abstract The demand for lightweight antennas in 5 G/6 G communication, wearables, and aerospace applications is rapidly growing. However, standard manufacturing techniques are limited in structural complexity and easy integration of multiple material classes. Here we introduce charge programmed multi-material additive manufacturing platform, offering unparalleled flexibility in antenna design and the capability for rapid printing of intricate antenna structures that are unprecedented or necessitate a series of fabrication routes. Demonstrating its potential, we present a transmitarray antenna composed of an interconnected, multi-layered array of dielectric/conductive S-ring unit cells, reducing 94% mass of conventional antenna configurations. A fully printed circular polarized transmitarray system fed by a source and a Risley prism antenna system operating at 19 GHz both show close alignment between testing results and numerical simulations. This printing method establishes a universal platform, propelling discovery of new antenna designs and enabling data-driven design and optimizations where rapid production of antenna designs is crucial.
Science & Technology - Other Topics↗
Design workflow of a symmetric traveling wave antenna for fast ion production on DD tokamaks
Initial computational plasma physics scoping and a finite element method antenna modeling design workflow for a symmetric center-fed high-field side high harmonic fast wave traveling wave array (TWA) antenna are reported here. The TWA is designed to generate a test population of fast deuterium ions in an existing D–D tokamak by heating neutral beam deuterium ions, accelerating them from 80 keV to several hundred keV. The resulting fast particles are tailored to mimic key reactor energetic particle parameters with regards to exciting Alfven eigenmode instabilities, allowing for a D–D tokamak like DIII-D or ASDEX-U to replicate reactor-relevant conditions experimentally. Initial scenario scoping for high single-pass absorption as well as good preferential fast ion damping relative to electron damping was completed using the ray-tracing/Fokker–Planck codes GENRAY and CQL3D. Python RF network analysis packages were used to create a custom TWA optimization tool to inform a COMSOL flat antenna design, and Petra-M was used to study cold plasma effects. The TWA produced by this workflow has several novel features when compared to previous TWA studies, including symmetric center feeding, and passive end straps for image current cancellation for reduced impurity production. We show here that the antenna design workflow can readily produce TWA antennas optimized for reflection coefficient, image current cancellation, and launched power spectrum shape; and that a population of fast ions can be generated in the correct region of parameter space, warranting future more detailed studies.
70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
AMAROK: A Radio Frequency Development Platform for High-Power, Full-Scale Positive Ion Sources for DIII-D Neutral Beam Injectors
Next-generation neutral beam injection (NBI) systems demand RF ion sources capable of efficiently coupling >120 kW at 2–4-MHz frequencies, yet existing designs face voltage standoff and impedance-matching challenges. To address this, the advanced multicoil antenna for RF operations at kilowatts (AMAROK) was developed as a high-power RF inductively coupled plasma (ICP) source delivering up to 200 kW in the 2–4-MHz range via four phase-controlled generators for flexible power sharing. Two antenna designs—a single-strap multiturn (MT) and a multistrap single-turn (ST) design—were evaluated to optimize resonance, impedance matching, and power coupling across plasma loads. Here, a semi-analytical self-resonant frequency (SRF) model, validated experimentally, predicts resonance trends for arbitrary turn counts and tubing diameters, enabling rapid antenna optimization. Strap-to-strap mutual inductance in the ST configuration showed strong spatial dependence, guiding generator operation and total load inductance. These insights informed a custom π -topology matching network, achieving stable impedance matching over a wide range of plasma-driven loads. Collectively, these results position AMAROK as a versatile testbed for advancing high-power RF source technology in fusion NBI applications.
DIII-D↗
Design and Engineering of LUPIN: A Test-Bed Radiofrequency Ion Source for Enhanced Neutral Beam Injection on DIII-D
The Large, Uniform Plasma for Ionizing Neutrals (LUPIN) is an RF inductively coupled plasma (ICP) chamber for demonstrating plasma performance of an RF ICP positive ion source upgrade for the DIII-D Neutral Beam Injection (NBI) system. LUPIN will be used to investigate ion source physics, including neutral gas dynamics, plasma density uniformity, interactions with Faraday shields, and power coupling to novel RF antenna designs. LUPIN has an RF generator capable of delivering 20 kW of power at 2 MHz, which is coupled into a cylindrical quartz vessel measuring 20 cm in length and 10 cm in radius. This configuration matches the power density requirements for a full-scale ion source. Target hydrogen and deuterium plasma densities exceeding 10 18 m -3 would relate to extracted ion current densities of 2100 A/m 2 for 10 s. Vacuum conductance and gas flow calculations predict a maximum achievable neutral gas flow rate of 1675 Pa·L/s at 5 Pa of He, which mimics the gas flow of the DIII-D NBI system. Designs have been developed for an internal Faraday shield to mitigate heat flux and ion sputtering on the dielectric vessel. Thermomechanical finite element simulations demonstrated the Faraday shield design to be capable of withstanding anticipated heat loads from worst-case operation scenarios. Results of upcoming experimental investigations on LUPIN will guide the design of a full-scale prototype for DIII-D integration.
Faraday shield↗
Design and Engineering of LUPIN: A Test-Bed Radio-Frequency Ion Source for Enhanced Neutral Beam Injection on DIII-D
The Large, Uniform Plasma for Ionizing Neutrals (LUPIN) is a radio-frequency (RF) inductively coupled plasma (ICP) chamber for demonstrating plasma performance of an RF ICP positive ion source upgrade for the DIII-D neutral beam injection (NBI) system. LUPIN will be used to investigate ion source physics, including neutral gas dynamics, plasma density uniformity, interactions with Faraday shields, and power coupling to novel RF antenna designs. LUPIN has an RF generator capable of delivering 20 kW of power at 2 MHz, which is coupled into a cylindrical quartz vessel measuring 20 cm in length and 10 cm in radius. This configuration matches the power density requirements for a full-scale ion source. Target hydrogen and deuterium plasma densities exceeding 10 18 m -3 would relate to extracted ion current densities of 2100 A/m 2 for 10s. Vacuum conductance and gas flow calculations predict a maximum achievable neutral gas flow rate of 1675 Pa ⋅ L/s at 5 Pa of He, which mimics the gas flow of the DIII-D NBI system. Designs have been developed for an internal Faraday shield to mitigate heat flux and ion sputtering on the dielectric vessel. Thermomechanical finite element simulations demonstrated the Faraday shield design to be capable of withstanding anticipated heat loads from worst-case operation scenarios. Finally, results of upcoming experimental investigations on LUPIN will guide the design of a full-scale prototype for DIII-D integration.
Faraday shield↗
Analysis of RF Sheath-Driven Tungsten Erosion at RF Antenna in the WEST Tokamak
This study applies the newly developed STRIPE (Simulated Transport of RF Impurity Production and Emission) framework to analyze tungsten (W) erosion at RF antenna structures in the WEST tokamak. STRIPE integrates SolEdge3x for edge plasma backgrounds, COMSOL for 3D RF sheath potentials, RustBCA for sputtering yields, and GITR for impurity transport and ion energy–angle distributions. Building on prior work by Kumar et al. (2025) Nuclear Fusion, 65, 076039, which validated STRIPE for WEST ICRH discharge #57877, the present study provides a spatially resolved assessment of gross W erosion at both Q2 antenna limiters under ohmic and ICRH conditions. Simulations using 2D SolEdge3x profiles in COMSOL capture rectified sheath potentials exceeding 300 V, leading to strong upper-limiter localization. Both poloidal and toroidal asymmetries are observed and attributed to RF sheath effects, with modeled erosion patterns deviating from experiment—highlighting sensitivity to sheath geometry and plasma resolution. Erosion is driven primarily by high-charge-state oxygen ions (O6+–O8+), while D+ plays a negligible role. Assuming a plasma composition of 1% oxygen and 98% deuterium, STRIPE predicts a 30-fold increase in gross W erosion from ohmic to ICRH phases, consistent with a >25-fold rise in W-I (400.9 nm) brightness. Quantitative agreement is within 5% in the ohmic phase and 30% under ICRH, demonstrating predictive capability. Importantly, the study shows that the magnitude of ICRH-driven W erosion depends strongly on the concentration of light impurities (O, B, N, C), which drive sputtering through high charge states. Cleaner plasma conditions with reduced impurity content are therefore expected to substantially mitigate antenna W sources in WEST and other toroidal fusion devices. These findings establish STRIPE as a predictive framework for RF-induced plasma–material interactions and support its application to reactor-scale antenna design.
Kumar, Atul [ORNL] (ORCID:0000000277475210)↗
ICRF near-field effects sensitivity to magnetic tilt-angle
This paper complements the study reported in G. Urbanczyk et al 2025 Nucl. Fusion 65 046018 by investigating how near-field effects from Ion Cyclotron Range of Frequency (ICRF) antennas depend on the magnetic geometry, particularly focusing on the sensitivity of rectified sheath potentials and associated impurity production to variations in magnetic field tilt-angle. Simulations were conducted using Petra-M, employing a flat model of the ASDEX Upgrade (AUG) three-strap antenna, and COMSOL, utilizing a curved model of the WEST antenna. Results demonstrate indications of sensitivity of the rectified sheath potentials and impurity sputtering to the alignment of Faraday screen bars with the magnetic field lines, emphasizing the necessity for careful consideration of geometric alignment in antenna design for fusion devices. This trend is consistent with experimental data measured with various diagnostics.
Urbanczyk, Guillaume [Universite de Lorraine, Nanc↗
Integrated modeling of RF-induced tungsten erosion at ICRH antenna structures in the WEST tokamak *
This paper introduces STRIPE (Simulated Transport of RF Impurity Production and Emission), an advanced modeling framework developed to analyze material erosion and the global transport of eroded impurities originating from radio-frequency (RF) antenna structures in magnetic confinement fusion devices. STRIPE integrates multiple physics modules: SolEdge3x for scrape-off-layer plasma profiles, COMSOL for 3D RF rectified sheath potentials, RustBCA for erosion yields and surface interactions, and global impurity transport for 3D ion energy-angle distributions and impurity transport. The framework is applied to an ion cyclotron RF-heated L-mode discharge (#57877) in the WEST tokamak, where it predicts a thirty-fold increase in gross tungsten erosion at antenna limiters during the transition from ohmic to ICRH operation. Additionally, under ICRH conditions, a tenfold enhancement in erosion is observed when comparing RF sheath effects to purely thermal sheath conditions. High-charge-state oxygen ions ($\mathrm{O}$ 6+ and above) are identified as the dominant contributors to tungsten sputtering. To validate the model, a synthetic diagnostic tool based on inverse photon efficiency (S/XB coefficients) from the ColRadPy collisional-radiative model enables direct comparison with spectroscopic measurements. Model predictions using a plasma composition of 1% oxygen and 99% deuterium show good agreement with observed W − I (400.9 nm) emission for discharge #57877, supporting the accuracy of the STRIPE framework. This study focuses specifically on gross erosion calculations to demonstrate STRIPE’s capabilities. Future extensions of this work will incorporate net erosion, re-deposition, self-sputtering effects, and whole-device modeling of sputtered tungsten impurity transport. STRIPE is also being applied to other RF-heated linear and toroidal devices, offering valuable insights for antenna design, impurity control, and performance optimization in next-generation fusion reactors.
70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
Applications of Artificial Intelligence to Radar
In this report, we survey the current intersection between the fields of radar technology and artificial intelligence. Three main areas are highlighted - synthetic aperture radar automatic target detection, waveform optimization, and antenna design. Literature relevant to these applications and beyond are discussed and compiled in an annotated bibliography.
47 OTHER INSTRUMENTATION↗
Automated design of an additive manufactured compact broadband antenna for plasma reflectometry
Broadband antennas operating in the gigahertz frequency range are regularly used for plasma reflectometry diagnostics. Due to a lack of space and unique diagnostic constraints, these antennas are often custom in design and frequency range. Recent advances in additive manufacturing of high temperature copper alloys allow for expanded freedom in design of these diagnostic antennas. In this work, a heuristic simulated annealing algorithm is used alongside 3-D finite element simulation to automate the design of a double ridged rectangular horn antenna for a reflectometry diagnostic on the DIII-D tokamak. Optimization of antenna performance given the design constraints results in a compact broadband (6-20+ GHz) antenna design. Measured transmission from the additively manufactured antenna matches simulation within reasonable error, and experimental plasma electron density profiles from the DIII-D high-field side scrape-off layer are shown.
Additive manufacturing↗
INNOVATIVE MAGNETO-ELECTRIC ANTENNA: AN ELECTRICALLY SMALL DESIGN FOR LOWER UHF APPLICATIONS
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Montoya, Anita Maria [Sandia National Laboratories↗
3D-Printed mmWave Quasi-Holographic Antenna for 2-D Beamforming
This paper presents the design and manufacturing of a novel 2D-scanning antenna that integrates a 3D-printed Rotman lens with a quasi-holographic leaky-wave antenna (HLWA). The proposed design achieved beam-scanning capabilities by leveraging the beamforming of the Rotman lens and the high-gain directive properties of the quasi-HLWA. The Rotman lens (RL) enables beam steering in the elevation plane by switching between input ports. The quasi-HLWA, designed using holographic principles, achieves frequency-controlled beam scanning in the azimuth plane. The entire antenna structure was fabricated using additive manufacturing with an Ink1092 substrate and silver ink for the conductive traces. This approach provides greater control over material placement and design freedom compared to traditional methods. A 25° transmission linear substrate taper was used to ensure good impedance matching between the Rotman lens and the quasi-HLWA, allowing greater gain while maintaining a good scanning range. The experimental results validate the 2D scanning capability of the proposed antenna. The antenna system provides coverage from −54° to 54° in the elevation θ plane and −28° to 28° in the azimuth plane ϕ , with a maximum measured gain of 21.3 dBi at 28 GHz with an average radiation efficiency η=60 %. The fabricated prototype was tested, and the performance was in good agreement with the simulated performance.
Rotman lens↗
Wireless Patch Antenna Characterization for Live Health Monitoring Using Machine Learning
Temperature monitoring in extreme environments, such as coal-fired power plants, was addressed by designing and testing wireless patch antennas for use in machine learning-aided temperature estimation. The sensors were designed to monitor the temperature and health of boiler systems. Wireless interrogation of the sensor was performed using a Vector Network Analyzer (VNA) and a pair of interrogation antennas to capture resonance behavior under varying thermal and spatial conditions with sensitivities ranging from 0.052 to 0.20 $\frac{𝑀𝐻𝑧}{°C}$. Sensor calibration was conducted using a Long Short-Term Memory (LSTM) model, which leveraged temporal patterns to account for hysteresis effects. The calibration method demonstrated improved performance when combined with an LSTM model, achieving up to a 76% improvement in temperature estimation error when compared with Linear Regression (LR). The experiments highlighted an innovative solution for patch antenna-based non-contact temperature measurement, which addresses limitations with conventional methods such as RFID-based systems, infrared, and thermocouples.
20 FOSSIL-FUELED POWER PLANTS↗
Analysis of RF Surface Loss in a Planar 2D Qubit
The Josephson junction and shunt capacitor form a transmon qubit, which is the cornerstone of modern quantum computing platforms. For reliable quantum computing, it is important how long a qubit can remain in a superposition of quantum states, which is determined by the coherence time (T1). The coherence time of a qubit effectively sets the "lifetime" of usable quantum information, determining how long quantum computations can be performed before errors occur and information is lost. There are several sources of decoherence in transmon qubits, but the predominant one is generally considered to be dielectric losses in the natural oxide layer formed on the surface of the superconductor. In this paper, we present a numerical study of microwave surface losses in planar superconducting antennas of different transmon qubit designs. An asymptotic method for estimating the energy participation ratio in ultrathin films of nanometer scales is proposed, and estimates are given for the limits of achievable minimum RF losses depending on the electrical properties of the surface oxide and the interface of the qubit with the substrate material.
75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
Antenna arrays for neutrino mass measurements with cyclotron radiation emission spectroscopy
Cyclotron Radiation Emission Spectroscopy (CRES) is a technique for precision measurements of kinetic energies of charged particles, pioneered by the Project 8 experiment to measure the neutrino mass using the tritium end-point method. It was recently employed for the first time to measure the molecular tritium spectrum and place a limit on the neutrino mass using a cubic-centimeter-scale detector. Future direct neutrino mass experiments are developing the technique to overcome the systematic and statistical limitations of current detectors. Here, this paper describes one such approach, namely the use of antenna arrays for CRES in free space. Phenomenology, detector design, simulation, and performance estimates are discussed, culminating with an example design with a projected sensitivity of 𝑚 𝛽 < 0.04 eV/𝑐 2 . Prototype antenna array measurements are also shown for a demonstrator-scale setup as a benchmark for the simulation. By consolidating these results, this paper serves as a comprehensive reference for the development and performance of antenna arrays for CRES.
Physics - Nuclear physics and radiation physics↗
Control of Energy Transport and Transduction in Photosynthetic Down-Conversion (Final Technical Report)
The research conducted under this contract focused on three areas related to control of energy transport and transduction in natural and synthetic light harvesting systems: (1) experimental and theoretical studies exploring the use of ultrafast laser pulse shaping to manipulate the initially excited states of multi-chromophore biological light harvesting networks and influence the early time energy transfer and electronic and vibrational relaxation pathways, (2) fundamental theoretical developments aimed at computing and analyzing the dynamics of excitations of complex heterogeneous environments and nano structures, and (3) joint experimental and theoretical design studies of artificial light harvesting materials exploring the influence of incorporating different types of organic layers in low dimensional lead halide perovskite materials on their hot carrier relaxation dynamics, and theoretical studies of the design of nano structured light harvesting antenna systems. These research projects supported the training of three theoretical and computational graduate students, one experimental graduate student, and one experimental post-doctoral researcher. The research has been published in seven peer reviewed papers and presented at several international meetings and workshops.
37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
Passive Wireless Sensors for Realtime Temperature and Corrosion Monitoring of Coal Boiler Components Under Flexible Operation (Final Technical Report)
Researchers at West Virginia University (WVU) propose to demonstrate inexpensive wireless, high-temperature sensors for real-time monitoring of the temperature and corrosion of metal components, which are commonly used in coal-fired boilers. This study presents the development of cost-effective wireless high-temperature sensors for real-time temperature and corrosion monitoring in coal-fired boilers' metal components. The focus is on fabricating and evaluating chipless radio-frequency identification (RFID) sensors capable of operating between 25-1300 ºC. Efforts were directed towards designing passive RFID sensor and interrogator antenna with a broad frequency range, optimizing a microstrip patch antenna sensor integrated into a "peel-and-stick" format for efficient application to various metal specimens without altering their geometry. Additionally, this research aimed to assess the sensor responses under accelerated high-temperature conditions, correlating corrosion and cracking mechanisms with sensor data. An investigation of through-wall data acquisition techniques was also planned, facilitating unobtrusive monitoring of sensor responses housed within metal enclosures. Ultimately, this work sought to establish a robust passive wireless sensor system for the continuous health monitoring of metal components in operational settings, thereby contributing to enhanced safety and efficiency in coal-fired power plants.
20 FOSSIL-FUELED POWER PLANTS↗