Manufacturing, Developments, and Constraints in Full 3-D Printing of Frequency-Selective Surface Using Low-Cost Open-Source Printer

A comprehensive study of developing a novel printing system using a low-cost open-source printer for fully 3D printing frequency selective surface is presented in this paper. The novel printing setup employs a low-cost printer to print a plastic based filament and a conductive silver ink paste simultaneously. As there were no printers available in the market for this application, the open-source Fused Filament Fabrication (FFF) printer was modified to accommodate two extruders mounted on the same extruder carriage. Techcon TS250 air pressure dispenser was employed for the extrusion of silver ink. Extension pieces for the extruder carriage were also 3D printed using a Fused Deposition Modelling (FDM) printer to reduce the production costs. A bandstop FSS comprising of square loop elements was designed to demonstrate the full fabrication. The FSS operated at a central frequency of 2.55 GHz and provided a good angle of response with wide bandwidths. Surface profiles of the printed FSS and substrate demonstrate the reliable fabrication of the FSS design. This full 3D printing method provides an economical, eco-friendly, swift, reliable, and viable substitute for the fabrication of FSS designs that could be highly customised in terms of fabricating three-dimensional FSS designs with reliable performances. The designs can be printed and deployed to reduce the drop in signal within an enclosed environment

3D Printing of Conformal Antennas for Diversity Wrist Worn Applications

This paper presents for the first time the application of 3D printing techniques for the development of conformal antennas for diversity wrist worn wireless communications. Three processes are described with the common challenge of depositing the metallic layers of the antennas on a bracelet fabricated using fuse filament fabrication (FFF). The first is a multistep process which combines adding a layer to smooth the surface of the band, aerosol jetting the metallic tracks, flash curing and then electroplating. The second combines painting the metallic layers by hand and then electroplating. The last process uses a single machine to fabricate both the bracelet and then the metallic layers by means of a direct write system with silver conductive ink. The wrist worn antennas are presented and its performances on the human wrist are discussed. All antennas cover 2.4 GHz and 5.5 GHz used for WLAN communication with the reflection coefficients less than ?10 dB. The diversity wrist worn antennas system is developed for the final two processes. Three WLAN antennas are fabricated at different positions and shape angles within the bracelet. In terms of communications systems, the advantage of this configuration is that it can increase coverage. The radiation patterns of the antenna are nearly omnidirectional in free space and directional on the human wrist. When the patterns of the three antennas are combined together, the coverage for the communication system improves. Simulation results of all antenna designs and studies using the finite integration technique (FIT) agree well with experimental measurement results. The main motivation of this work is to investigate alternative additive manufacturing methods for the development of conformal diversity antennas on customized 3D printed parts