Additive Manufacturing for Antenna Applications

This thesis presents methods to make use of additive manufacturing (AM) or 3D printing (3DP) technology for the fabrication of antenna and electromagnetic (EM) structures. A variety of 3DP techniques based on filament, resin, powder and nano-particle inks are applied for the development and fabrication of antennas. Fully and partially metallised 3D printed EM structures are investigated for operation at mainly microwave frequency bands. First, 3D Sierpinski fractal antennas are fabricated using binder jetting printing technique, which is an AM metal powder bed process. It follows with the introduction of a new concept of sensing liquids using and non-planer electromagnetic band gap (EBG) structure is investigated. Such structure can be fabricated with inexpensive fuse filament fabrication (FFF) in combination with conductive paint. As a third method, inkjet printing technology is used for the fabrication of antennas for origami paper applications. The work investigates the feasibility of fabricating foldable antennas for disposable paper drones using low-cost inkjet printing equipment. It then explores the applicability of inkjet printing on a 3D printing substrate through the fabrication of a circularly polarised patch antenna which combines stereolithography (SLA) and inkjet printing technology, both of which use inexpensive machines. Finally, a variety of AM techniques are applied and compared for the production of a diversity WLAN antenna system for customized wrist-worn application

Developing Novel 3D Antennas Using Advanced Additive Manufacturing Technology

In today’s world of wireless communication systems, antenna engineering is rapidly advancing as the wireless services continue to expand in support of emerging commercial applications. Antennas play a key role in the performance of advanced transceiver systems where they serve to convert electric power to electromagnetic waves and vice versa. Researchers have held significant interest in developing this crucial component for wireless communication systems by employing a variety of design techniques. In the past few years, demands for electrically small antennas continues to increase, particularly among portable and mobile wireless devices, medical electronics and aerospace systems. This trend toward smaller electronic devices makes the three dimensional (3D) antennas very appealing, since they can be designed in a way to use every available space inside the devise. Additive Manufacturing (AM) method could help to find great solutions for the antennas design for next generation of wireless communication systems. In this thesis, the design and fabrication of 3D printed antennas using AM technology is studied. To demonstrate this application of AM, different types of antennas structures have been designed and fabricated using various manufacturing processes. This thesis studies, for the first time, embedded conductive 3D printed antennas using PolyLactic Acid (PLA) and Acrylonitrile Butadiene Styrene (ABS) for substrate parts and high temperature carbon paste for conductive parts which can be a good candidate to overcome the limitations of direct printing on 3D surfaces that is the most popular method to fabricate conductive parts of the antennas. This thesis also studies, for the first time, the fabrication of antennas with 3D printed conductive parts which can contribute to the new generation of 3D printed antennas

Particle swarm optimized, 3-d-printed, wideband, compact hemispherical antenna

© 2002-2011 IEEE. A three-dimensional (3-D)-printed, wideband, compact hemispherical-shaped antenna is presented. It consists of a driven strip monopole and several parallel near-field resonant parasitic (NFRP) strips that reside on the surfaces of a hemispherical shell. The monopole strip lies on the interior surface; the NFRP strips lie on the exterior one. This arrangement facilitates the requisite stable near-field capacitive coupling between them over a wide frequency range. The particle swarm optimization algorithm is used to define the lengths and locations of these NFRP strips to achieve its optimized operational bandwidth around 700 MHz given its compact size. The hemispherical shell was 3-D printed with acrylonitrile butadiene styrene resin; the strips were applied to it with silver paste. This prototype was tested. The measured results, in agreement with their simulated values, demonstrate that it achieves a 17.97% -10 dB fractional impedance bandwidth over which stable realized gain values, near 3.5 dBi, are attained. With its low-cost fabrication and attractive performance characteristics, this 3-D printed antenna is suitable for indoor multipath wireless communication systems

Additive Manufactured Antennas and Novel Frequency Selective Sensors

The research work carried out and reported in this thesis focuses on the application of additive manufacturing (AM) for the development antennas and novel frequency selective surfaces structures. Various AM techniques such as direct writing (DW), material extrusion, nanoparticle conductive inks are investigated for the fabrication of antennas and FSS based sensors. This research has two parts. The first involves the development of antennas at the microwave and millimetre wave bands using AM techniques. Inkjet printing of nanoparticle silver inks on paper substrate is employed in the fabrication of antennas for an origami robotic bird. This provides an exploration on the practicability of developing foldable antennas which can be integrated on expendable robots using low-cost household inkjet printers. This is followed using Aerosol jet printing in the fabrication of fingernail wearable antennas. The antennas are developed to operate at microwave and millimetre wave bands for potential use in 5G Internet of Things (IoT) or body-centric networks. The second part of the research work involves the development of frequency selective sensors. Trenches have been incorporated on an FSS structure to produce a new concept of liquid sensor. The sensor is fabricated using standard etching techniques and then using FDM method in conjunction with nanoparticle conductive ink. Finally, a new concept displacement sensor using an FSS coupled with a retracting substrate complement is introduced. The displacement sensor is a 3D structure which is conveniently fabricated using AM techniques

Miniaturization and Optimization of Electrically Small Antennas, with Investigation into Emergent Fabrication Techniques

With the paradigm shift in personal communications favouring wireless over wired, the demand for efficient, low-cost, and compact antennas is booming. The proliferation of mobile electronic devices (laptops and tablets, fitness trackers, ‘smart’ phones and watches), together with the desire for longer battery life, poses a unique challenge to antenna designers; there is an unavoidable trade-off between miniaturization and performance (in terms of range and efficiency). The size of an antenna is inherently linked to the wavelengths(s) of the electromagnetic waves that it must transmit and/or receive. Due to real-estate pressures, most modern antennas found in electronics are classed as electrically small, i.e. operating at wavelength(s) many times greater than their largest dimension. Theory dictates that the best possible compromise between size and performance is achievable when an antenna fully occupies a volume, the radius of which is defined by an imaginary sphere circumscribing its largest dimension. This Thesis demonstrates the design and optimization of low-cost, easy-to-fabricate, electrically small antennas through the integration of novel digitated structures into a family of antennas known as inverted-F. The effects of these digitated structures are catalogued using simulated models and measured prototypes throughout. Whereas the limitations of traditional industrial processes might once have constrained the imaginations of antenna designers, there is now tremendous potential in successful exploitation of emergent manufacturing processes – such as additive manufacturing (or 3D printing) – to realize complex, voluminous antenna designs. This Thesis also presents pioneering measured results for three-dimensional, electrically small antennas fabricated using powder bed fusion additive manufacturing. The technology is demonstrated to be well suited for prototyping, with recommendations provided for further maturation. It is hoped that these promising early results spur further investigation and unleash bold new avenues for a new class of efficient, low-cost, and compact antennas

Circular polarised antenna fabricated with low-cost 3D and inkjet printing equipment

The fabrication of a patch antenna using low-cost 3D printing equipment is presented. A circular polarised (CP) patch antenna is manufactured by combining inkjet printing and stereolithography (SLA) technology. The substrate has been fabricated by curing photosensitive resin while the patch element of the antenna has been inkjet printed using silver ink. The printed antenna satisfies the required reflection coefficient, axial ratio and radiation pattern at 1575 MHz. The aim is to demonstrate an inexpensive technology that could be used for the fabrication of antennas on customised 3D printed substrates. The performance of the antenna is summarised through simulations and experimental results

Additively Manufactured Shape-changing RF Devices Enabled by Origami-inspired Structures

The work to be presented in this dissertation explores the possibility of implementing origami-inspired shape-changing structures into RF designs to enable continuous performance tunability as well as deployability. The research not only experimented novel structures that have unique mechanical behaviour, but also developed automated additive manufacturing (AM) fabrication process that pushes the boundary of realizable frequency from Sub-6 GHz to mm-wave. High-performance origami-inspired reconfigurable frequency selective surfaces (FSSs) and reflectarray antennas are realized for the first time at mm-wave frequencies via AM techniques. The research also investigated the idea of combining mechanical tuning and active tuning methods in a hybrid manner to realize the first truly conformal beam-forming phased array antenna that can be applied onto any arbitrary surface and can be re-calibrated with a 3D depth camera.Ph.D

Electromagnetic characterisation of conductive 3D-Printable filaments for designing fully 3D-Printed antennas

Additive manufacturing (AM) 3D-printing technology is increasingly bringing benefits even in electromagnetics, with interesting prospects of application. Apart from the use of additive manufacturing for realising dielectric components of suitably shaped antennas, the ambitious target is, undoubtedly, the fully 3D realisation of radiofrequency and microwave circuits as well as radiating structures, including, therefore, conductive parts. In this regard, 3D-printable filaments with interesting conductive properties are being produced. However, their rigorous conductivity characterisation is still missing, making it difficult to estimate the real behaviour of the final 3D printed electromagnetic device. To fill this gap, the conductivity of one of the most interesting conductive filaments, named Electrifi, is first experimentally evaluated in a frequency range as large as 0.72-6 GHz, accounting also for its roughness. Then it has been validated by designing, realising, and testing three fully 3D-printed antennas. Specifically, two bow-tie antennas, operating at 2.8 and 4 GHz, respectively, and an ultrawideband antenna, borrowed from the existing literature, operating between 1 and 7 GHz. The good agreement between simulated and measured results demonstrates the reliability of the performed electrical conductivity characterisation, even in the design of efficient radiating structures entirely realised with thermoplastic materials with copper nanoparticle additives

Evaluating the Effectiveness of Planar and Waveguide 3D-Printed Antennas Manufactured Using Dielectric and Conductive Filaments

3D printing is a technology suitable for creating electronics and electromagnetic devices. However, the manufacturing of both dielectric and conductive parts in the same process still remain a challenging task. This study explores the combination of 3D printing with traditional manufacturing techniques for antenna design and fabrication, giving the designer the advantage of using the additive manufacturing technology only to implement the most critical parts of a certain structure, ensuring a satisfying electromagnetic performance, but limiting the production cost and complexity. In the former part of the study, the focus is on three proximity-coupled patch antennas. It demonstrates how hybrid devices made of metal, dielectric, and 3D-printed (using Fused Filament Fabrication) conductive polymers can be successfully simulated and created for different operating frequency bands. In the latter part, the study compares three prototypes of a 5G-NR, high gain, and wideband waveguide antenna: respectively a fully 3D printed one made of electrifi (which is the most conductive commercial 3D-printable filament), an all-metal one, and a hybrid (3D-printed electrifi & metal) one. The results show a 15% reduction in efficiency when using the all-Electrifi configuration compared to all-metal one, and a 4-5% reduction when using the hybrid version

Electromagnetic characterisation of conductive 3D-Printable filaments for designing fully 3D-Printed antennas

Additive manufacturing (AM) 3D-printing technology is increasingly bringing benefits even in electromagnetics, with interesting prospects of application. Apart from the use of additive manufacturing for realising dielectric components of suitably shaped antennas, the ambitious target is, undoubtedly, the fully 3D realisation of radiofrequency and microwave circuits as well as radiating structures, including, therefore, conductive parts. In this regard, 3D-printable filaments with interesting conductive properties are being produced. However, their rigorous conductivity characterisation is still missing, making it difficult to estimate the real behaviour of the final 3D printed electromagnetic device. To fill this gap, the conductivity of one of the most interesting conductive filaments, named Electrifi, is first experimentally evaluated in a frequency range as large as 0.72–6 GHz, accounting also for its roughness. Then it has been validated by designing, realising, and testing three fully 3D-printed antennas. Specifically, two bow-tie antennas, operating at 2.8 and 4 GHz, respectively, and an ultrawideband antenna, borrowed from the existing literature, operating between 1 and 7 GHz. The good agreement between simulated and measured results demonstrates the reliability of the performed electrical conductivity characterisation, even in the design of efficient radiating structures entirely realised with thermoplastic materials with copper nanoparticle additives