Fabrication of Conformal FSS Radome Based on MOPSO inverse design and mask spraying

Abstract

Conformal electromagnetic structures play an important role in modern aerospace and communication systems by combining spatial filtering capability with aerodynamic compatibility. However, transferring planar frequency-selective surfaces (FSSs) onto complex curved profiles can induce resonant-frequency drift and geometric distortion, creating challenges for both electromagnetic co-design and precision fabrication. Here, we introduce a closed-loop framework that seamlessly integrates artificial intelligence-driven inverse design with an automated robotic spraying process. By employing a multi-objective particle swarm optimization (MOPSO) algorithm, we achieve the global optimal geometric matching of FSS elements within a multi-dimensional parameter space, effectively resolving the inherent conflict between in-band high transmission and out-of-band rejection. The optimized designs are rapidly translated into physical prototypes using a high-precision, non-contact multi-degree-of-freedom robotic spraying system. Free-space measurements demonstrate that our fabricated X-band conformal radome exhibits exceptional angular stability and a transmittance exceeding 0.9 up to a 26° scanning angle. This fully automated “design-to-fabrication” paradigm paves a scalable and cost-effective pathway for the next generation of multifunctional 3D meta -devices and stealth radomes.