3D-Printed Electromagnetic Structures for Antenna and Millimeter-Wave Engineering Applications

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3D printing is a powerful technique to build objects with complex geometries that are difficult, costly and sometimes not even possible to manufacture with conventional machining methods. Yet, it is comparatively recently that 3D printing technology has started to be explored for antennas and high-frequency electromagnetic (EM) structures-a field in which precision machining of bulk metal and dielectric materials using computer numerically controlled (CNC) drills and lathes remains widespread. In this research program we will investigate 3D-printed EM dielectric structures with advanced functionalities and reconfigurability using dielectric fluids. The outcomes of this research program are aimed at users of high-performance front-end wireless equipment for whom system reconfigurability and weight reduction can provide a decisive competitive advantage. This applies to manufacturers of communications and radar hardware for civilian and defence aircraft, satellites and maritime vessels all of which carry multiple antenna systems on-board. The frequency bands that we will use for prototype design are 8-12 GHz (X band) and 18-40 GHz (K and Ka bands), which cover point-to-point gigabit wireless links (i.e. tower to tower), broadband satellite communications, remote sensing and aeronautical/maritime radionavigation. The 3D printing methods we will use are fused deposition modeling (FDM) and stereolithography (SLA). For the fluidic aspects of this research, a 20-channel fluidic pumping system from Darwin Microfluidics Corp. (Paris, France) to source fluid in and out of the structures. All test and measurement of the EM structures will take place at Queen's University's laboratory facilities. Over the course of this program, highly qualified personnel trainees will learn advanced lab skills that include: antenna radiation pattern measurements, antenna efficiency measurements, design of antenna test mounts, 3D printing methods, antenna construction, PCB manufacturing and design of microfluidic systems. Each subject area described in this proposal reflects technologies that are used in industry today and they will serve to demonstrate that 3D printed dielectric structures can deliver excellent performance on par with what exists at present but at a fraction of the cost and time needed to fabricate them.