3D-printed low-cost, low-loss microwave components up to 40 GHz

Rohrdantz, Benjamin; Rave, Christian; Jacob, Arne F.

doi:10.1109/mwsym.2016.7540122

Cited by 15 publications

(5 citation statements)

References 7 publications

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“…Integrating multiple 3-D printed components together offers the important advantage of removing impedance mismatch losses between flanges. For example, both Rohrdantz et al [10] and later Dimitriadis et al [11], demonstrated a non-tunable 4-element antenna array at Ka-band (26.5 to 40 GHz). In contrast, our group recently demonstrated a mechanically-tunable 3-D printed beam-steerable 4-element phased-array antenna at Ku-band [8].…”

Section: Introductionmentioning

confidence: 99%

3-D Printed Plug and Play Prototyping for Low-Cost Sub-THz Subsystems

et al. 2022

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Polymer-based additive manufacturing using 3-D printing for upper-millimeter-wave (ca. 100 to 300 GHz) frequency applications is now emerging. Building on our previous work, with metal-pipe rectangular waveguides and free-space quasi-optical components, this paper brings the two media together at G-band (140 to 220 GHz), by demonstrating a compact multi-channel front-end subsystem. Here, the proof-of-concept demonstrator integrates eight different types of 3-D printed components (30 individual components in total). In addition, the housing for two test platforms and the subsystem are all 3-D printed as single pieces, to support plug and play development; offering effortless component assembly and alignment. We introduce bespoke free-space TRM calibration and measurement schemes with our quasi-optical test platforms. Equal power splitting plays a critical role in our multi-channel application. Here, we introduce a broadband 3-D printed quasi-optical beamsplitter for upper-millimeter-wave applications. Our quantitative and/or qualitative performance evaluations for individual components and the complete integrated subsystem, demonstrate the potential for using consumer-level desktop 3-D printing technologies at such high frequencies. This work opens-up new opportunities for low-cost, rapid prototyping and small-batch production of complete millimeter-wave front-end subsystems.

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Section: Introductionmentioning

confidence: 99%

3-D Printed Plug and Play Prototyping for Low-Cost Sub-THz Subsystems

et al. 2022

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“…Building from polymer substrates has the advantages of weight savings and inexpensive material, but can come at the expense of performance, depending on the (EM) application [18]. For this reason, metallization of these parts by means of plating, painting and sputtering conductive material, either selectively or fully, can be effective, so long as the surface roughness of the components does not interfere with desired frequencies of interest [19][20][21]. Requirements of greater non-load-bearing mechanical stability and skin depth limitations motivate the need for fully metallic objects, which can improve components such as waveguides and free-standing antennas [22][23][24][25].…”

Section: Introductionmentioning

confidence: 99%

A copper pyramidal fractal antenna fabricated with green-laser powder bed fusion

Johnson

Burden

Shaffer³

et al. 2022

Prog Addit Manuf

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Recent advances in additive manufacturing have enabled a new generation of electromagnetic applications to flourish. Complex geometries for dielectrics and conductors can now be simulated and rapidly fabricated from digital data. Powder bed fusion of metals is arguably the most widely adopted additive process by industry and can provide intricately-detailed structures in a wide range of high performance alloys. Copper and copper alloys have remained a challenge in this additive process, as the typical laser wavelength (approximately 1070 nm) used fails to provide sufficient absorption. Moreover, the high thermal conductivity of copper does not allow for the required heat generation for a stable melt pool. However, the recent commercial introduction of the green laser (515 nm wavelength) is enabling the printing of copper, which is particularly interesting for electrical and electromagnetic applications due to the high electrical conductivity and solderability. This paper describes the use of a green laser powder bed fusion system used to fabricate a complex fractal Sierpinski gasket ground structure with an isolated internal pyramid antenna built simultaneously—within and dielectrically isolated from the external ground element: a ship-in-the-bottle design paradigm. The electromagnetic performance, surface finish, dimensional compliance, and conductivity were measured and reported to inform the design of freestanding, geometrically-complex antennas.

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“…Although, the resulting structures are not conductive, the smooth surface finish is well suited for subsequent plating of conductive metal layers. Both consumer and production printers are available for the process and can develop quality antenna components at relatively low costs [23]. Vat photopolymerization has proved fruitful for multiple waveguides designed to operate in the GHz frequency range [24], [25].…”

Section: Introductionmentioning

confidence: 99%

Digital Manufacturing of Pathologically-Complex 3D Printed Antennas

et al. 2019

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In the last decade, the proliferation of new 3D printing technologies has enabled the fabrication of complex geometries in manifold materials for novel applications. One discipline that has been explored extensively in the context of additive manufacturing is electromagnetic devices such as antennas. Difficultto-fabricate geometries are now possible and can deliver new antenna functionality and extend performance (e.g., lower frequency resonance in small volumes, wider bandwidth, narrow-beam directionality, and so on). Coupled with accurate 3D electromagnetic simulations, a new paradigm is emerging for antenna design and manufacture. Starting from a seed geometry, the state space can now be explored to identify new combinations and permutations of electromagnetically-beneficial shapes through multiple simulation iterations. Subsequently, the identified structures can be further validated and improved through rapid manufacturing using 3D printing for hardware evaluation in an anechoic chamber. However, to fully benefit from this emerging paradigm, an up-to-date survey of the most recent metal processes is required. This survey would determine which processes are well suited for building the next generation of antennas. For this purpose, a variety of metal 3D printing was employed to fabricate benchmark antennas with pathological geometries, including thin walls, overhanging features, and large aspect ratios. This survey can inform designers about potential structures to serve in novel antennas. A total of five processes have been preliminarily explored including selective laser melting, binder jetting, and plated vat photopolymerization, all of which delivered different advantages and disadvantages in terms of mechanical and electromagnetic performance. INDEX TERMS 3D printing, 3D printed antennas, 3D Hilbert curve, additive manufacturing, antenna radiation pattern, binder jetting, dipole antennas, fractal antenna, multifrequency antennas, powder-bed fusion, ultra high frequency, UHF, vat photopolymerization.

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3D-printed low-cost, low-loss microwave components up to 40 GHz

Cited by 15 publications

References 7 publications

3-D Printed Plug and Play Prototyping for Low-Cost Sub-THz Subsystems

3-D Printed Plug and Play Prototyping for Low-Cost Sub-THz Subsystems

A copper pyramidal fractal antenna fabricated with green-laser powder bed fusion

Digital Manufacturing of Pathologically-Complex 3D Printed Antennas

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