Structural optimization of jet plasma polymerization reactor based on response surface methodology

Abstract Jet plasma polymerization represents a significant advancement in polymeric films, facilitating the development of novel functional materials. The study introduces a novel computational framework based on response surface methodology (RSM) for the structural optimization of continuous jet plasma polymerization reactors. A parameterized computational model integrating key geometric features of cylindrical reactors and direct-injection nozzles was developed, and three-level central composite design was employed to capture non-linear interactions, while jet flow simulations revealed the governing influence of reactor geometry on film formation outcomes. Three film formation criteria were defined as objective functions, and through a parametric sensitivity analysis, five geometric parameters were identified as critical geometric parameters. Multi-criteria optimization was then performed independently using both the multi-objective genetic algorithm (MOGA) and screening algorithms (SAs), whose results were applied to a quadratic response surface model. Comparative analysis demonstrated that MOGA outperformed SA in identifying geometric configurations that simultaneously optimize film integrity and maximize deposition rates. The findings of this study establish a validated RSM-based protocol for jet plasma polymerization reactors design, and enhances the predictability of reactor performance in the field of plasma-enhanced material fabrication.