Freeform Optimization of an Ultrasonic Horn Coupled to an Airborne MEMS Transducer

We designed an ultrasonic horn using a physics-based freeform optimization method to achieve the target frequency response of an airborne ultrasonic MEMS transducer operating in transmitting mode. The radial profile of the ultrasonic horn was parametrized using a Bezier curve, and its shape was optimized using a genetic algorithm. A computationally fast compact model of the full system, wherein the horn was described analytically using transmission line theory, was used to calculate the frequency response of the transducer and evaluate the optimization objective. The result shows very good agreement with the experimental measurement of a realized prototype.