Pulsed Cold Spray System for Physical Unclonable Function Generation

Physical Unclonable Functions (PUFs) have gained remarkable attention as a promising anti-counterfeiting solution by generating unique physical fingerprints or trust anchors derived from inherent manufacturing randomness and authenticated verification processes. Pulsed Cold Spray (PCS)—an emerging advanced manufacturing process—leverages cyclic compressed turbulent gas pulses to propel particles with high kinetic energy, enabling the creation of arbitrary patterns at each pulse that are inherently unique and physically unclonable. This study investigates the potential of PCS for generating PUFs. The gas and particle dynamics within the PCS system was analysed, and the geometry of particles at specific distances from the nozzle was visualized based on simulation results. Key parameters for achieving an optimal PUF were identified, and the simulation outcomes were validated through comparison with experimental data, confirming the conditions necessary for optimal PUF generation.