Low-cost 3D-printed 240 GHz plastic lens fed by integrated antenna in organic substrate targeting sub-THz high data rate wireless links

Lacombe, Elsa; Gianesello, Frédéric; Bisognin, Aimeric; Luxey, Cyril; Titz, Diane; Gulan, Heiko; Zwick, Thomas; Costa, Jorge R.; Fernandes, Carlos A.

doi:10.1109/apusncursinrsm.2017.8072045

Cited by 15 publications

(7 citation statements)

References 4 publications

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“…cleanroom based, while mass production is still possible at very low fabrication cost. Table 3 compares figure-ofmerits between the all-photopolymer lens antenna reported here and other state-of-the-art lens structures [15]- [16], [18], [24], [27] published to date.…”

Section: Measurement Resultsmentioning

confidence: 99%

220-320 GHz Hemispherical Lens Antennas Using Digital Light Processed Photopolymers

et al. 2019

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This paper presents a 220-320-GHz hemispherical lens antenna fabricated using photopolymer-based additive manufacture and directly fed by the standard WR-3 rectangular waveguide without any additional waveguide extension. The microfabrication process is based on digital light processing rapid prototyping using the Monocure 3DR3582C resin-based photocurable polymer. This gives various key advantages, including ease of antenna fabrication, manufacturing speed, and cost-effectiveness due to its rapid fabrication capability. Even though the photopolymer is found to have a loss tangent of 0.034 at 320 GHz, the all-polymer lens antennas still achieve a fractional bandwidth of 37%, covering the whole 220-320-GHz WR-3 waveguide band with a measured gain of approximately 16 dBi at 0 • over the whole band. A measured return loss of better than 14 dB is achieved from 220 to 320 GHz with a half-power beamwidth of approximately 12 • , which is relatively constant over the whole WR-3 band. INDEX TERMS Lens antenna, digital light processing, terahertz antennas.

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Section: Measurement Resultsmentioning

confidence: 99%

220-320 GHz Hemispherical Lens Antennas Using Digital Light Processed Photopolymers

et al. 2019

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“…Lenses were successfully fabricated using the settings determined in the method section. Previous works [8][9][10]12,13] have shown the fabrication of hyperbolic lenses to be achievable; however, this is the first instance where wavelength-matched AR structures were also 3D printed. FFF 3D printing was shown to be capable of producing AR structures of sufficiently small dimensions for 60 GHz application.…”

Section: Lens Fabricationmentioning

confidence: 94%

“…The most common low-cost 3D printing technique is Fused Filament Fabrication (FFF) in which a thermoplastic filament material is heated and extruded through a nozzle that selectively deposits material for the specific geometry desired. This allows for complex, bespoke geometries to be readily produced out of materials suitable for millimeter wavelengths, and previous works have exploited this for the production of radar lenses [8][9][10][11][12][13][14].…”

Section: Introductionmentioning

confidence: 99%

3D Printed Radar Lenses with Anti-Reflective Structures

Friel

Gerling-Gerdin

Nilsson

et al. 2019

Designs

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Background: The purpose of this study was to determine if 3D printed lenses with wavelength specific anti-reflective (AR) surface structures would improve beam intensity and thus radar efficiency for a Printed Circuit Board (PCB)-based 60 GHz radar. This would have potential for improved low-cost radar lenses for the consumer product market. Methods: A hyperbolic lens was designed in 3D Computer Aided Design (CAD) software and was then modified with a wavelength specified AR structure. Electromagnetic computer simulation was performed on both the ‘smooth’ and ‘AR structure’ lenses and compared to actual 60 GHz radar measurements of 3D printed polylactic acid (PLA) lenses. Results: The simulation results showed an increase of 10% in signal intensity of the AR structure lens over the smooth lens. Actual measurement showed an 8% increase in signal of the AR structure lens over the smooth lens. Conclusions: Low cost and readily available Fused Filament Fabrication (FFF) 3D printing has been shown to be capable of printing an AR structure coated hyperbolic lens for millimeter wavelength radar applications. These 3D Printed AR structure lenses are effective in improving radar measurements over non-AR structure lenses.

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“…According to [5], it is a printing process widely used to produce mechanical and electronic devices, even for high-frequency electronics ranging from a few MHz to optical regimes [6]- [10]. More specifically, it is being used in many sectors like medical, personal healthcare, dentistry, consumer goods and wireless communications [11], [13]- [16]. AM processes have been extensively used recently in the development of microwave, millimeter-wave, and even terahertz devices.…”

Section: Introductionmentioning

confidence: 99%

Harmonized Rapid Prototyping of Millimeter-Wave Components Using Additive and Subtractive Manufacturing

Chudpooti

Savvides

Duangrit

et al. 2022

IEEE Trans. Compon., Packag. Manufact. Technol.

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In this paper, a harmonized fabrication and assembly process combining additive and subtractive manufacturing is introduced for the rapid manufacture of millimeter-wave components, especially those using hollow substrate integrated waveguide (HSIW). HSIW has been shown to have some significant advantages for millimeter-wave communications, radar and sensing systems, but its fabrication can be challenging. To pattern the metallic layers that form the top and bottom HSIW walls, as well as other structures such as microstrip lines and landing pads for integrated circuits and passive components, a subtractive fabrication process using a water-jet laser cutter was employed. To fabricate the dielectric substrate using low-cost Acrylonitrile Butadiene Styrene (ABS), with cavities for the waveguides, a Stratasys PolyJet 3D printer (Objet1000) was used. The HSIW components were then assembled using commercially-available through-substrate copper transitions, completely eliminating the process of throughsubstrate via-hole formation and metallization. The manufacturing techniques conventionally used for these vias are generally expensive and intricate at millimeter-wave frequencies. Therefore, the proposed fabrication and assembly process in this paper decreases the overall fabrication cost and complexity, and it is shown that this is achieved without compromising the performance of the millimeter-wave HSIW components. The measurement results show that a propagation loss of 13.55 dB/m (0.01355 dB/mm) is achieved for the first HSIW prototype, which is believed to be among the lowest propagation losses ever reported at these frequencies. The proposed harmonized fabrication and assembly technique has also a strong potential, by combining the advantages of additive and subtractive manufacturing techniques, to realize a new class of millimeter-wave components with the possibility of manufacturing conformal and flexible component shapes, based on the materials used.

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Low-cost 3D-printed 240 GHz plastic lens fed by integrated antenna in organic substrate targeting sub-THz high data rate wireless links

Cited by 15 publications

References 4 publications

220-320 GHz Hemispherical Lens Antennas Using Digital Light Processed Photopolymers

220-320 GHz Hemispherical Lens Antennas Using Digital Light Processed Photopolymers

3D Printed Radar Lenses with Anti-Reflective Structures

Harmonized Rapid Prototyping of Millimeter-Wave Components Using Additive and Subtractive Manufacturing

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