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A method for the fabrication of graded dielectrics within a structural composite is presented. This system employs an ultrasonic powder deposition head to print high dielectric powders onto a woven fabric composite substrate. It is shown how this system can integrate 3D variations of dielectric properties at millimeter resolution within a mechanically rugged substrate. To conclude, the system’s practical application is demonstrated with experimental results from a graded index lens.

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Woven fabric composites provide an attractive platform for integrating electromagnetic functionality-such as conformal load-bearing antennas and frequency selective surfaces-into a structural platform. One practical fabrication method for integrating conductive elements within a woven fabric composite system involves using additive manufacturing systems such as screen printing. While screen printing is an inherently scalable, flexible and cost effective method, little is known about the high frequency electrical properties of its conductive inks when they are embedded within the woven fabric composite. Thus, we have completed numerical and experimental studies to determine the electrical conductivity of screen printable conductive inks that are embedded within this composite. We have also performed mechanical studies to evaluate how printing affects the structural performance of the composite.

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The University of Delaware Department of Mechanical Engineering curriculum includes a senior design project, where teams address real design challenges facing local firms. The SURVICE Engineering Company tasked a team to design an improved metrology vector bar for use with an indoor global positioning system (iGPS) computer system. This vector bar needed to be ergonomic, easy to use, and easy to manufacture. To fulfill these requirements, metrics for a smaller, lighter, and more ergonomically designed Multi-Function Vector Bar were established. To encompass these metrics, four different subsystems were identified and integrated into a final design. Of these systems, emphasis was placed on a new ergonomic handle designed through an iterative process. New features were added to the handle to facilitate a decrease in human error and an increase in functionality. Multiple handle models were designed and tested to accomplish this. The final handle design resulted in a balanced, lighter, and more comfortable prototype that had two control buttons and indicator lights.