Simulation and Optimisation of Microwave Energy Distribution in Plasma Reactors

Bachelor’s thesis, master’s thesis, project work or research laboratory

© IKV

Thematic Classification of your Thesis:

By depositing functional coatings, the surface properties of polymer materials can be tailored to specific application requirements. Such modifications may improve gas barrier performance, scratch resistance, wettability, and chemical resistance, thereby expanding the range of potential applications. As a result, plasma-based technologies have emerged as enabling technologies in sectors including automotive engineering, packaging, medical technology, and electronics, contributing to the development of more sustainable polymer products.

One particularly promising approach is Plasma-Enhanced Chemical Vapour Deposition (PECVD). In this process, a process gas is ionised through the coupling of microwave energy, generating a plasma containing highly reactive species. These species initiate a cascade of fragmentation and reaction mechanisms that ultimately lead to the formation of the desired functional coating on the substrate surface.

The efficiency and quality of the coating process are strongly influenced by the spatial distribution of microwave energy within the reactor. A homogeneous microwave field distribution is essential for uniform plasma generation and for achieving consistent and reproducible coating properties. To maximise process efficiency while minimising the required microwave power input, the positioning of the microwave coupling points must be carefully optimised. Therefore, the analysis and optimisation of microwave field distributions within PECVD reactors represent an important step towards the development of more energy-efficient and economically viable plasma coating processes.

Scope of your Thesis:

As part of this thesis, a simulation model will be developed to analyse the distribution of microwave fields within a plasma reactor. The project will begin with the development of a two-dimensional model representing a rectangular reactor geometry equipped with a single point-source microwave excitation. Based on this initial configuration, the number and spatial arrangement of the microwave coupling points will be systematically varied in order to investigate their influence on the resulting electromagnetic field distribution. In addition, the effect of introducing an object into the reactor chamber on the field distribution will be examined.

Subsequently, the model will be extended to incorporate more complex reactor and substrate geometries. The positions of the microwave coupling points will be treated as optimisation parameters and evaluated with regard to their impact on the homogeneity and spatial distribution of the microwave field. Depending on the scope, the complexity of the simulation model will be progressively increased to enable the investigation of increasingly realistic reactor configurations.

Work Packages:

The scope and schedule of the thesis will be individually agreed upon and tailored to your prior knowledge and interests. In addition, there is the possibility of addressing the topic in a modified form within the framework of a research laboratory or a project-based module.

Your Profile:

• Enrolled in a technical or scientific degree program (e.g., Simulation Sciences, Chemical Engineering, Mechanical Engineering, Industrial engineering, Physics, Mathematics, Materials Science, Environmental Engineering…)
• Willingness to engage with and acquire knowledge of new topics and problem areas related to plasma technology
• An independent and structured approach to working
• Initial experience with simulation work is desirable, but not essential

AG Plasma offers you a dynamic, young team in which you and your skills can grow during the course of your thesis, with clear objectives and diverse tasks. If you are interested in contributing to the field of plastics processing with your creative ideas, please feel free to get in touch with me!