3D Printed Radar Lenses with Anti-Reflective Structures

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. © 2019 by the authors. Licensee MDPI, Basel, Switzerland