AI-Native RF Module Designer - Features & usage¶

This document provides detailed information about the features and usage of the RF Module Designer.

🚀 Features¶

Core Stackup Generation¶

Multiple HDI Types: Single lamination, HDI-1, HDI-2, HDI-3, HDI-4 stackups
Smart Layer Management: Automatic core/prepreg assignment with thickness optimization
Enhanced Material Library: Comprehensive thermal properties and professional guidance
Glass Transition Temperature (Tg) data for all materials
Professional Categorization: Aerospace (🚀), Automotive (🚗), Standard (🔌) grade materials
Manufacturing Compatibility: Reflow and lead-free process validation
Quick Thermal Analysis: Always-visible thermal summary with expert recommendations
Material Database: Comprehensive database with FR4, Rogers, and MEGTRON6 ultra-low loss materials
MEGTRON6 Integration: Panasonic's premium ultra-low loss material for high-performance RF applications
Frequency Coverage: 1-40 GHz with frequency-dependent properties
18 Thickness Options: Complete range from 0.050mm to 0.925mm
Thermal Properties: Tg=185°C with comprehensive thermal database integration
Material Property Updates: Material dk/df values now update correctly when changing materials
Thickness Control: Target finished thickness with automatic layer adjustment
Auto-thickness Matching: When changing materials, automatically finds closest available thickness

RF Module Designer - Phase-Based Workflow¶

5-Phase Design Process: Guided workflow from requirements to final schematic
Phase I: Define System & Module Specifications
Phase II: Block Diagram & Component Selection
Phase III: RF Link Budget & Simulation
Phase IV: Passive Circuit Design & PCB Integration
Phase V: Schematic Creation & Verification
Progress Tracking: Visual progress bar and phase completion indicators
Data Persistence: Automatic save with localStorage (survives browser refresh)
Flexible Navigation: Navigate backward to edit completed phases
Complete RF Chain Design: AI-driven RF module generation with comprehensive component selection
Frequency Coverage: 100 MHz to 40 GHz with frequency-specific component optimization
Power Management: Regulatory compliance with application-specific power limits
Component Database: Extensive RF component library with verified specifications and current pricing
KiCad Integration: Full KiCad project generation with schematic, PCB, and project files
BOM Generation: Complete Bill of Materials with pricing and availability
Modular Architecture: Clean separation of UI, data, and business logic
Smart Trace Width Optimization: Automatic RF trace sizing based on component pad dimensions

Standalone Calculators (workflow-free)¶

Standalone Impedance Calculator (/app/impedance-calculator): Microstrip/stripline/GCPW with mini-stackup form, copper roughness Dk correction, frequency sweep. Feature-flagged via VITE_FF_STANDALONE_IMPEDANCE.
Standalone Link Budget Calculator (/app/link-budget-calculator): Cascaded gain, output power, Friis cascaded NF, gain-referred reciprocal-sum OIP3, and P1dB headroom — runs without Phase I/II of the 5-phase workflow. Three coexisting input modes:
Manual: user-defined stages (gain / NF / P1dB / OIP3 / loss).
Auto-design: target frequency + Pout + topology (tx-basic, tx-preamped, rx-basic) → POST /api/agent/select-batch returns a real chain from validated DB parts. Auto-runs on a 500 ms debounce.
Browse DB: per-stage "Pick part" modal hitting POST /api/components/search with debounce + cache.
All three modes share one LinkBudgetStage[] model and one compute pipeline; outputPowerDbm overrides honor the orchestrator's P1dB-aware power flow.
Feature-flagged via VITE_FF_STANDALONE_LINK_BUDGET (default ON). Plan: docs/planning/standalone_link_budget_calculator/.
Patch Antenna Calculator (/tools/antenna-calculator, public signed-out page; also in-app): rectangular microstrip patch synthesis (Balanis cavity model) from frequency + substrate, with inset-feed geometry, live top-view preview, and optional Nx×Ny planar array (array factor, beamwidths, grating-lobe check, beam-pattern plot).
Planar Filter Calculator (/tools/planar-filter-calculator, public signed-out page; also in-app): planar filter synthesis — LPF (stepped-impedance, open-stub) and BPF (parallel-coupled) in microstrip or stripline — with per-section geometry output. One backend engine (services/planar_filter_service.evaluate_planar_filter) backs the page, the API route, and the agent tool; unimplemented topologies (interdigital/combline) are refused, never approximated.

Design Tools & Analysis¶

Impedance Calculator: Real-time microstrip and stripline impedance calculations
Via Padstack Technology: HDI microvia specifications and visualization
DFM Validation: Design for Manufacturing checks and recommendations
Advanced Thermal Analysis: Professional thermal design validation
CTE Analysis: Coefficient of thermal expansion validation and mismatch detection
Operating Temperature Ranges: Application-specific limits (Consumer, Automotive, RF/Microwave)
Heat Capacity Analysis: Thermal mass calculations and time constant estimation
Thermal Validation: Industry-standard design rule checking with professional recommendations
Performance Optimized: Instant analysis with intelligent layer filtering
PCB Design Rule Checker: Validate KiCad PCB files against manufacturer capabilities
Support for JLCPCB, PCBWay, and TTM Technologies
Client-side validation (no file uploads)
Real-time design rule checking

AI Chat Assistant (Gemini)¶

Smart Chat Onboarding: Gemini-powered AI chat with intelligent onboarding experience
Starter Prompts: 6 clickable prompt cards (2-column grid) adapted to project context — default prompts for new users, contextual prompts when project data exists
Action Cards: Styled cards rendered inline in chat messages for completed tool calls (rf_specs, stackup_config, block_diagram, solver, surrogate, design_template)
Auto-Open Welcome: Chat sidebar auto-opens on first visit with a local welcome message and pulsing blue dot indicator
Enhanced System Prompt: Guided design knowledge, 7 common RF design templates, and comparison prompts for trade-off questions
Apply Design Template Tool: One-click application of RF design templates (sets frequency, material, layers) via apply_design_template tool call
Chat Prominence: "Start Designing with AI" CTA button that auto-hides after first interaction
Live AI Agent: The AI-native shell (/app/agent) drives the design end-to-end via a streamed multi-turn tool-call loop — the scripted demo mode was removed
Public demo: a signed-out /demo/agent replay of a real captured agent run (no Gemini quota; reuses the production SSE + action-card path). Backend backend/routes/demo.py, frontend frontend/src/components/Demo/; flags FF_PUBLIC_DEMO / VITE_FF_PUBLIC_DEMO (default off in code, enabled via root .env)
Feature Flags: Each capability toggles independently via environment variables
VITE_FF_CHAT_STARTER_PROMPTS (default: true)
VITE_FF_CHAT_AUTO_OPEN (default: true)

Export & Integration¶

KiCad Export: Direct export to KiCad PCB format (.kicad_pcb, .kicad_pro)
RF Module Projects: Complete KiCad project generation with schematics, PCB, and symbols
ADS Export: Substrate files for Keysight ADS simulation with embedded MagicON sidecar metadata
ODB++ Export: Binary format with proper directory structure, tested and verified with Keysight ADS
Gerber Export: Full Gerber + drill file export via KiCad CLI (dual-mode: upload .kicad_pcb or auto-generate from stackup)
IPC-2581 Export: Manufacturer-agnostic XML format via KiCad CLI
HFSS Export: PyAEDT script generator for Ansys HFSS 3D Layout
MagicON Internal Export: Native .magicon-internal.json with full stackup, impedance targets, design rules, and manufacturing metadata
PDF Reports: Comprehensive stackup documentation with AI reasoning section and visualizations

📋 How to Use¶

1. PCB Stackup Generation¶

Select stackup type (Single, HDI-1, HDI-2, etc.)
Configure layers, frequency, and target thickness
Choose materials from the comprehensive database
Generate and visualize your stackup

2. RF Module Generation¶

Navigate to "RF Module Generator" tab
Configure your RF requirements (frequency, power, application)
Select components from the extensive RF database
Generate complete KiCad project with schematic and PCB
Download ready-to-use KiCad project files

3. Design Analysis¶

Impedance: Calculate trace impedances for your stackup
Via Technology: Review HDI via specifications
DFM: Check design manufacturability
Thermal: Analyze heat dissipation requirements

3a. Standalone Calculators (no project required)¶

Impedance Calculator (/app/impedance-calculator): Quick microstrip/stripline/GCPW math without leaving the calculator screen.
Link Budget Calculator (/app/link-budget-calculator):
Open from the main nav.
Pick a mode — Manual (type stages directly), Auto (set topology + frequency + target Pout, debounced auto-run), or Browse (Manual table with per-row "Pick part" → modal search of the component DB).
Watch cascaded gain / NF / OIP3 / P1dB headroom + per-stage waterfall update live.
Mode switches preserve the stage list, so you can auto-design then hand-tweak rows.

4. PCB Design Rule Checking¶

Navigate to the "Design Rule Check" tab
Upload your .kicad_pcb file
Select manufacturer profile (JLCPCB, PCBWay, TTM)
Click "Check My Design" for instant validation
Review trace width, via drill, and layer count compliance

5. Export Options¶

KiCad: Export directly to KiCad PCB format
RF Projects: Generate complete RF module projects
ADS: Generate substrate files for simulation with sidecar metadata
ODB++: Manufacturing format with embedded design intelligence
Gerber: Via KiCad CLI with drill files
IPC-2581: Manufacturer-agnostic XML format
HFSS: PyAEDT scripts for Ansys HFSS
MagicON Internal: Full design intelligence JSON for re-import
PDF: Create comprehensive documentation with AI reasoning

6. AI Chat Assistant¶

Open the Gemini chat sidebar (auto-opens on first visit)
Click a starter prompt card or type your own question
Review action cards for tool call results inline
Or open the AI-native shell (/app/agent) to watch the agent design end-to-end
Apply design templates with one click from chat