Design thinking-driven development of a modular X-Band antenna using multi-material 3D printing

Abstract

This study presents the development of a modular parasitic patch antenna using 3D printing and the Design Thinking (DT) methodology. The antenna structure, manufactured with insulating polycarbonate and conductive silver lines, incorporates a reflector, main antenna, and parasitic patch. The study demonstrates the successful application of DT and Design for Manufacture and Assembly (DfMA) principles in optimizing manufacturing efficiency and assembly effectiveness. Simulations and measurements confirm the satisfactory performance of the 3D printed antenna, with a minimum reflection coefficient of -15 dB, efficiency reaching up to 75%, and gain falling within the range of conventionally fabricated antennas. The integration of insulator and conductor materials in 3D printing facilitates the manufacturing of complex structures, while the modular design enables easy installation and customization. This research contributes to the advancement of 3D printing technology for microwave applications, offering cost-effective and efficient manufacturing solutions for industrial antenna production.