Fabrication of Millimeter Wave Components Via Ceramic Stereo‐ and Microstereolithography Processes

Abstract

International audienceComplex ceramic parts, designed by 3D electromagnetic simulations for microwave devices of high performances, are difficult, even impossible, to elaborate by classical ceramic processing routes. This paper demonstrates the direct fabrication of useful complex microwave devices in millimeter and submillimeter wavelength domains, with a high dimensional resolution, by the numerical techniques of stereolithography and microstereolithography. Alumina and zirconia formulations have been developed with a powder loading 450 vol%, a suitable rheology to spread thin (25-50 lm) and homogeneous layers, and with a sufficient reactivity to UV for polymerization. Devices built with a satisfying manufacturing accuracy have presented excellent experimental electrical behaviors in good agreement with the theoretical ones

Additive Manufacturing of Ceramic‐Based Materials

“…8. From left to right: different CSL structures that can be employed as molds for turbine airfoils (fused silica), [217] as microwave-guides (zirconia), [196] and as bone implants (hydroxyapatite). [205] Fig.…”

High solids loading ceramic colloidal dispersions in UV curable media via comb-polyelectrolyte surfactants

“…Nanometer and submicrometer ceramic particles are advantageous for high resolution microstructures, surface quality and reduced sintering temperatures. Although few particle types can be efficiently dispersed in organic UV curable monomer mixtures [10], special surfactants are frequently needed to increase particle solids loading to the levels required for ceramic processing (>40 vol%) [2,[4][5][6][7][8][9].…”

“…Stereolithography relies on relatively UV transparent dispersions having viscosities lower than 5 Pa s (30 1/s) [1]. Numerous studies of dispersions of micrometer and submicrometer powders in organic and aqueous media have been made [1][2][3][4][5][6][7][8][9]. Organic systems are advantageous due to the wide choice of monomers and oligomers for composite formulation and fast curing.…”

Review of 3D Printed Millimeter-Wave and Terahertz Passive Devices

“…Frequency shift is caused by the dimensional tolerance in printing and shrinkage in postsintering. In 2008, a D-band (110-170 GHz) EBG resonator was printed by the micro SLA ( SLA) technology on alumina [11]. This work pushed the boundary of 3D printed devices from mmWave to THz spectrum.…”