Few examples of individual polymer-based 3-D printed quasi-optical component types have been previously demonstrated above ca. 100 GHz. This paper presents the characterization of polymer-based 3-D printed components and complete subsystems for quasi-optical applications operating at G-band (140 to 220 GHz). Two low-cost consumer-level 3-D printing technologies (vat polymerization and fused deposition modeling) are employed, normally associated with microwave frequencies and longer wavelength applications. Here, five different quasi-optical component types are investigated; rectangular horn antennas, 90º off-axis parabolic mirrors, radiation absorbent material (RAM), grid polarizers and dielectric lenses. As an alternative to conventional electroplating, gold-leaf gilding is used for the polarizer. A detailed investigation is undertaken to compare the performance of our 3-D printed antennas, mirrors and RAM with their commercial equivalents. In addition, a fully 3-D printed, RAM-lined housing with central two-axis rotational platform is constructed for performing two-port measurements of a quasi-optical horn-mirrorpolarizer-mirror-horn subsystem. Measured results generally show excellent performances, although the grid polarizer is limited by the minimum strip width, separation distance and metallization thickness. The ultralow cost, 'plug and play' housing is designed to give a fast measurement setup, while minimizing misaligning losses. Its RAM lining is designed to suppress reflections due to diffraction from components under test that may cause adverse multi-path interference. Our work investigates each component type at G-band and integrates them within subsystem assemblies; operating at frequencies well above those normally associated with low-cost consumer-level 3-D printing technologies. This opens-up new opportunities for rapid prototyping of complete low-cost front-end quasi-optical upper-millimeter-wave subsystems.
This paper introduces the first fully 3-D printed tunable microwave subsystem, consisting of 26 circuit elements. Here, a polymer-based 3-D printed Ku-band 4-element steerable phased-array antenna with fully integrated beam-forming network is demonstrated. Polyjet was adopted for fabricating the main body of the subsystem, as it is capable of producing a geometrically complex structure with high resolution over a large volume. Low-cost fused deposition modeling was chosen to manufacture the dielectric inserts and brackets for the phase shifters. The measured radiation pattern revealed that the phased-array antenna subsystem has total beam steering angles of 54 • and 52 • at 15 GHz and 17 GHz, respectively. Excellent input return loss behavior was observed across the optimum operational frequency range of 15 to 17 GHz, with a worst-case measured return loss of 12.9 dB. This work clearly shows the potential of using 3-D printing technologies for manufacturing fully integrated subsystems with complex geometric features.
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