In this study, we developed a series of second-order gradient overlap-coupling octagonal superconducting quantum interference device (SQUID) current sensors for transition edge sensor (TES) applications. According to the requirements of TESs, we designed various parameters of SQUID current sensors, including different Josephson junction (JJ) sizes, different hysteresis and screening parameters, input coils with different inductances. The superconducting loop, input coil, and feedback coil of the SQUID current sensors adopt a second-order gradient structure, which can effectively enhance their anti-interference electromagnetic capability. Further, all the coupling structures between the superconducting loop and input/feedback coil adopt overlap-coupling octagonal structures, which can effectively enhance the coefficient of coupling mutual inductance. A series of second-order gradient SQUID current sensors overlap-coupled with input coils of 1.5, 2.5, and 5.5 turns based on Nb/Al-AlOx/Nb Josephson junctions were successfully fabricated on 2-inch silicon wafers by optimising the fabrication processes. From the simulation results, a minimal magnetic coupling factor of 0.02 between the feedback coil and input coil is obtained in the overlapped structure of the SQUID current sensor with an input coil of 1.5 turns; thus the magnetic interference between the feedback coil and input coil in this design is negligible. According to the measurement results at liquid-helium temperatures, SQUID current sensors with second-order gradient overlap-coupling octagonal structures have an excellent capability to weaken environmental electromagnetic interference. The SQUID current sensor with an input coil of 5.5 turns has the smallest current sensitivity, 2.4 μA/Φ0 and lowest current noise, 1 pA/√Hz compared with those of other input coils of different turns. The SQUID current sensor with an input coil of 2.5 turns has the lowest flux noise, 0.3 μΦ0/√Hz, and the lowest coupled noise energy, 11 h, among all the three different input coils, which are balanced results between the input inductance and the device noise. SQUID current sensors with second-order gradient overlap-coupling octagonal structures show low flux noise, low current noise, and low coupled noise energy, which can be compared with the state-of-art SQUID current sensor worldwide, and can satisfy the requirements of TES applications.
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