With the transition toward the ‘New Space’ era, there has been a sharp increase in demand for microsatellites performing high-value missions, such as Earth observation and communication relays. To ensure precise orbit maintenance and attitude cont...
With the transition toward the ‘New Space’ era, there has been a sharp increase in demand for microsatellites performing high-value missions, such as Earth observation and communication relays. To ensure precise orbit maintenance and attitude control of these satellites, highly reliable propulsion systems are essential. Among these, the Microwave Electro-thermal Thruster (MET) has gained significant attention as a next-generation alternative; its electrodeless operation fundamentally eliminates electrode erosion, ensuring high specific impulse and extended operational life. Existing MET research has primarily focused on performance verification of simplified geometries or efficiency analysis using global models. In this study, we performed geometric optimization and electromagnetic-plasma coupled analysis to maximize the performance of a 2.45 GHz MET. First, the cavity height, dielectric slab thickness and position, and antenna insertion depth were selected as key design variables to analyze their correlations with electromagnetic resonance characteristics. In particular, to ensure the reliability of the simulation model, an empirical calibration process was introduced. Material properties were inversely estimated based on VNA measurements of a fabricated cavity and fed back into the numerical model. This approach allowed for the determination of an optimal geometry that reflects actual energy losses and material characteristics, resulting in significantly improved return loss and a substantial reduction in the input power required to achieve a target electric field strength. Furthermore, the plasma discharge characteristics under various operating conditions were investigated using the calibrated model. The analysis revealed that the self-shielding effect, occurring when electron density exceeds the cutoff critical density, is a primary mechanism determining plasma localization and discharge transition. Notably, it was found that the operating pressure is a more dominant factor than input power in determining the plasma potential barrier height and energy confinement efficiency. In addition, an analysis of heating characteristics due to the skin effect physically demonstrated that the high-temperature electron generation zone and the actual gas heating zone are spatially separated. This study clearly presents the organic correlation between MET design and operational variables by combining empirically-validated model calibration with multi-physics analysis. The elucidated shielding phenomena and spatial separation of heating zones are expected to serve as critical design guidelines for maximizing energy efficiency and ensuring device durability under diverse propellant conditions in the future.