Development and Characterization of a Plastic 3D-Printed only external-layer Metal-Coated Waveguide Antenna Array

Betancourt, Diego; Galvis-Salzburg, Carlos; Weinmann, Frank

doi:10.23919/eucap51087.2021.9411209

Cited by 3 publications

(2 citation statements)

References 11 publications

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“…For our prototype prints, we have used 3D printers with polylactic acid (PLA) 1 plastic filament at a fine layer height (< 0.1 mm) as well as a gradual infill strategy with an overall density of less than 10 % [45]. In a second production step, as exemplified in [46] for the manufacturing of an antenna array, a conductive coating is applied to the reflector surface in order to generate metal-like reflection characteristics. Instead of galvanization, we propose to spray-paint the conductive coating, e.g., using silver-coated copper [47], to reduce the complexity for the rapid prototyping.…”

Section: A Passive Reflector Manufacturing Conceptmentioning

confidence: 99%

Holistic Enlightening of Blackspots With Passive Tailorable Reflecting Surfaces for Efficient Urban mmWave Networks

et al. 2023

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Mitigating outage regions is of particular interest for emerging millimeter-wave (mmWave) and future sub-terahertz frequency cellular networks. Whereas smart radio environments based on metasurfaces constitute a key concept for 6G research, current networks cannot be served as new control procedures are required. Although small prototypes are already emerging, costs will be higher for the dense deployment of reconfigurable intelligent surfaces (RISs) than for passive reflectors. It is argued that passive reflectors can be used to effectively, cost-efficiently, and permanently boost connectivity in well-defined service areas. Leveraging the advantages of 3D printing and spray-painted conductive varnish, we introduce the Holistic Enlightening of bLackspots with passIve reflectOr moduleS (HELIOS) approach which is characterized by its scalability and parametrizability to meet the reflection requirements derived from sophisticated network planning. These slim reflectors meet the core criteria of ease of installation and minimal visual impact on the cityscape, which are imperative for market success. Our measurements-based comparison of prototypes against typical metal/aluminum reflectors shows at least equal reflectivity at a higher practicality of the proposed manufacturing process. The conducted simulation study validates the modular reflector pattern design process and finds a trade-off between the reflector efficiency and the minimum protrusion depth, which relates to the number of modules in the designated mounting area. An urban ray-tracing simulationbased case study further underlines the high applicability of the proposed approach, with the growth of the beyond line-of-sight (LOS) connectivity region being nearly twice as large for a site-tailored HELIOS configuration as for a simple reflector plate.INDEX TERMS Millimeter-wave, passive reflector, beyond line-of-sight connectivity, additive manufacturing.

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Section: A Passive Reflector Manufacturing Conceptmentioning

confidence: 99%

Holistic Enlightening of Blackspots With Passive Tailorable Reflecting Surfaces for Efficient Urban mmWave Networks

et al. 2023

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“…In general, such antennas consist of several parts produced separately by expensive machining techniques, which are then assembled by dip brazing, taking particular care to avoid losses due to misalignment. The development of additive layer manufacturing (ALM) methods, such as stereolithography (SLA) or direct metal laser sintering (DMLS), now offers a broad range of possibilities to realize shapes that could not be made by conventional processes, and thus permits the design of innovative [3,4] and low-cost [5][6][7] 3D microwave components. Regarding 3D metal printing, the capabilities offered by the DMLS process can be deployed to produce monolithic components in one step with better temperature resistance than SLA associated with a metal plating process [8].…”

Section: Introductionmentioning

confidence: 99%

Design of a Slotted Waveguide Antenna Based on TE20 Mode in Ku-Band Suitable for Direct Metal Laser Sintering

et al. 2022

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This paper describes the design of a novel Ku-band slotted waveguide antenna (SWA), taking into consideration the advantages and drawbacks of using a 3D direct metal laser sintering (DMLS) process. Indeed, the DMLS process makes it possible to produce a SWA with 64 radiating slots and its feeding network in a single and monolithic process. However, considering the lack of accuracy of the process, the whole design must be completely thought out and planned to avoid sensitive dimensions. Coupling irises inside such structures are elements of major sensitivity in this regard, so the radiating waveguides in the present work were designed to be TE20 ones, avoiding this kind of iris. Thus, a TE10 to TE20 converter was designed to be implemented in the overall power supply structure of an antenna array made up of four linear SWAs with 16 slots each. Both the elementary 16-slot SWA and the complete SWA with the feeding network were manufactured using DMLS. At a resonant frequency of 15 GHz, the measured realized gain is 22.26 dB with sidelobe levels below 10.1 dB. The measured reflection coefficient is lower than −12.6 dB at the center frequency. These measured performances confirm the proof of concept.

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A comprehensive review on surface modifications of polymer‐based 3D‐printed structures: Metal coating prospects and challenges

Gautam,

Gogoi,

Kongnyui

et al. 2024

Polymers for Advanced Techs

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The production of complex structures out of a variety of materials has undergone a revolution due to the rapid development of additive manufacturing (AM) technology. Initially confined to applications such as magnetic actuators and two‐dimensional electric or electronic circuits, the convergence of 3D printing and metallization methods has emerged as a revolutionary approach. This synergy facilitates the creation of functional and customizable metal‐polymer hybrid structures characterized by high strength, lightweight properties, intricate geometric designs, and superior surface finish. These structures also exhibit enhanced electrical and thermal conductivity, as well as optical reflectivity. This paper reviews techniques to improve the effectiveness of 3D‐printed polymer antennas and structures by using various techniques of metallization. The metallization processes are examined, and a classification based on the materials employed is presented to facilitate comparisons that highlight the optimal utilization of materials for the fabrication of 3D‐printed polymer structures. The main emphasis here is on the effectiveness of different processes in terms of deposition, bonding strength, electrical conductivity, and various characteristics of metallic coatings developed on polymers. This review contributes an in‐depth analysis of the latest developments in 3D printing and metallization techniques specifically applied to polymer antennas and structures. The exploration extends to potential applications, challenges encountered, and future prospects within this dynamic field. As AM and metallization continue to evolve, this study aims to provide a comprehensive understanding of the state‐of‐the‐art methodologies and their implications for the future of polymer‐based structures and antennas.

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Development and Characterization of a Plastic 3D-Printed only external-layer Metal-Coated Waveguide Antenna Array

Cited by 3 publications

References 11 publications

Holistic Enlightening of Blackspots With Passive Tailorable Reflecting Surfaces for Efficient Urban mmWave Networks

Holistic Enlightening of Blackspots With Passive Tailorable Reflecting Surfaces for Efficient Urban mmWave Networks

Design of a Slotted Waveguide Antenna Based on TE20 Mode in Ku-Band Suitable for Direct Metal Laser Sintering

A comprehensive review on surface modifications of polymer‐based 3D‐printed structures: Metal coating prospects and challenges

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