A structurally supportive miniaturized low-weight (≤150 g) radiofrequency switch mode amplifier developed to power the small diameter Pocket Rocket electrothermal plasma micro-thruster called MiniPR is tested in vacuum conditions representative of space to demonstrate its suitability for use on nano-satellites such as "CubeSats." Argon plasma characterization is carried out by measuring the optical emission signal seen through the plenum window vs. frequency (12.8-13.8 MHz) and the plenum cavity pressure increase (indicative of thrust generation from volumetric gas heating in the plasma cavity) vs. power (1-15 Watts) with the amplifier operating at atmospheric pressure and a constant flow rate of 20 sccm. Vacuum testing is subsequently performed by measuring the operational frequency range of the amplifier as a function of gas flow rate. The switch mode amplifier design is finely tuned to the input impedance of the thruster (∼16 pF) to provide a power efficiency of 88% at the resonant frequency and a direct feed to a low-loss (∼10 %) impedance matching network. This system provides successful plasma coupling at 1.54 Watts for all investigated flow rates (10-130 sccm) for cryogenic pumping speeds of the order of 6,000 l.s −1 and a vacuum pressure of the order of ∼2 × 10 −5 Torr during operation. Interestingly, the frequency bandwidth for which a plasma can be coupled increases from 0.04 to 0.4 MHz when the gas flow rate is increased, probably as a result of changes in the plasma impedance.
This paper presents the design, modeling and characterization of 3D printed air core inductors for high frequency power electronics circuits. The use of 3D modeling techniques to make passive components extends the design flexibility and addresses some of the fabrication limitations of traditional processes. Recent work [1]-[9] has demonstrated the feasibility of incorporating air core inductors in high frequency (>10 MHz) switching power converters. These implementations have used discrete wire wound solenoids and toroids, and planar components that use Printed Circuit Board (PCB) traces or microfabrication techniques to make air core inductors. However, realizations of such components have limitations in performance and applicability including open paths conducive to the flow of leakage fields, and difficulties in achieving optimal cross-section to minimize loss. Along with the current effort of involving 3D printing technology to make inductors [10], [11], we propose the use of 3D printing and casting/plating techniques as a simple and accessible alternative that adds flexibility and functionality to air core inductor design for high frequency power conversion at moderate to high power (e.g. tens to thousands of watts) and high voltage (greater than 100 V) levels. In this paper, we present several examples of air core inductors realized using 3D printing and casting/plating techniques to give an idea of the geometries that are possible to design. Moreover, we show that some of these designs can lead to improved electrical performance.The paper also describes the tools used by the authors to design, fabricate and characterize the electromagnetic performance of the air core inductors. The software used to generate the 3D scaffolds for the inductors are freely available and easily accessible. Readers are encouraged to explore more possibilities of geometries that can lead to better performance with the ease of manufacturing. As progress in additive manufacturing continues, we envision 3D printing of a complete scaffold structure that after plating (or casting) will contain all resonant passive components of an RF switching converter. Toward this goal, we present a 70 W prototype 27.12 MHz resonant inverter that incorporates some of the 3D printed components developed for this work.Index Terms-3D printed air core inductor, high frequency power converters.
Progress in satellite technologies is ongoing and eventually finds applications back on Earth. Electric propulsion systems have been proven effective on large scale satellites (NASA DAWN) with better propellant efficiency than chemical or cold gas propulsion, and if miniaturized can be promising for long term operation of nano-satellites (e.g., CubeSats) in low Earth orbit or in deep space (NASA MarCO). However, the power supplies often used to power these electric thrusters, particularly those involving radiofrequency (RF) plasma, typically comprise power inefficient linear mode RF power amplifiers (e.g., class AB). These are simple systems designed to operate reliably under a wide range of loads for versatility, but they suffer low power efficiencies when operating at conditions significantly different from the nominal operating point. The required bulky and heavy thermal management components deem these electric propulsion systems impossible to fit on board nano-satellites. Here we present a compact and efficient switched mode dc-RF power inverter integrated with an electro-thermal plasma micro-thruster for nano-satellite (e.g., Cubesats) propulsion. The integrated system can serve as side panels and structural support of CubeSats, saving precious on-board volume for propellant and/or payloads. A complete assembly has been operationally tested in a space simulation system. This development opens a route for a new generation of power supplies applicable to the space sector, the microelectronics industry as well as the field of bioengineering.
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