A method for the fabrication of graded dielectrics within a structural composite is presented. This system employs an ultrasonic powder deposition head to print high dielectric powders onto a woven fabric composite substrate. It is shown how this system can integrate 3D variations of dielectric properties at millimeter resolution within a mechanically rugged substrate. To conclude, the system’s practical application is demonstrated with experimental results from a graded index lens.

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We describe a new methodology for creating flat lenses operating in the microwave spectrum using a custom designed additive manufacturing system. This method utilizes a novel dry powder 3D printing system to achieve graded index lenses integrated within a structural composite. We also describe a new iterative dot patterning algorithm to achieve a desired graded dielectric distribution, and we compare the iterative dot patterning algorithm to other dot patterning techniques. Computational and experimental results are provided validating the design and fabrication process.

The ability to fabricate multifunctional devices that combine good structural properties with embedded electromagnetic functionality has many practical applications, including antireflective surfaces for structural radomes, load bearing conformal antennas, integrated RF transmission lines and passive beam forming networks. We describe here a custom made 3D printer that can print high dielectric constant ceramic powders within a low-loss structural composite substrate to produce mechanically robust parts with integrated graded dielectric properties. We fabricated a number of these parts and evaluated their anisotropic dielectric properties by determining the complete permittivity tensor of the printed samples as a function of local powder weight. This data was then experimentally validated using two practical examples: a Chebyshev antireflective stack and a 2D passive beamsteering network. The results of both electromagnetic systems displayed acceptable agreement between the simulated and measured results. This agreement shows that powder printing is a potential approach for fabricating spatially graded dielectric electromagnetic systems.

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