Digital Manufacturing of Pathologically-Complex 3D Printed Antennas
In the last decade, the proliferation of new 3D printing technologies has enabled the fabrication of complex geometries in manifold materials for novel applications. One discipline that has been explored extensively in the context of additive manufacturing is electromagnetic devices such as antennas...
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doaj-4dbdd2137d054cba8387f0af552c0a212021-04-05T17:00:29ZengIEEEIEEE Access2169-35362019-01-017393783938910.1109/ACCESS.2019.29068688675738Digital Manufacturing of Pathologically-Complex 3D Printed AntennasKerry Johnson0https://orcid.org/0000-0003-3455-6464Michael Zemba1Brett P. Conner2Jason Walker3Edward Burden4Kirk Rogers5Kevin R. Cwiok6Eric Macdonald7Pedro Cortes8Advanced Manufacturing Research Center, Youngstown State University, Youngstown, OH, USANASA Glenn Research Center, Cleveland, OH, USAAdvanced Manufacturing Research Center, Youngstown State University, Youngstown, OH, USAAdvanced Manufacturing Research Center, Youngstown State University, Youngstown, OH, USAAdvanced Manufacturing Research Center, Youngstown State University, Youngstown, OH, USAM&P Gravity Works LLC, North Lima, OH, USAKeselowski Advanced Manufacturing, Statesville, NC, USAAdvanced Manufacturing Research Center, Youngstown State University, Youngstown, OH, USAAdvanced Manufacturing Research Center, Youngstown State University, Youngstown, OH, USAIn the last decade, the proliferation of new 3D printing technologies has enabled the fabrication of complex geometries in manifold materials for novel applications. One discipline that has been explored extensively in the context of additive manufacturing is electromagnetic devices such as antennas. Difficult-to-fabricate geometries are now possible and can deliver new antenna functionality and extend performance (e.g., lower frequency resonance in small volumes, wider bandwidth, narrow-beam directionality, and so on). Coupled with accurate 3D electromagnetic simulations, a new paradigm is emerging for antenna design and manufacture. Starting from a seed geometry, the state space can now be explored to identify new combinations and permutations of electromagnetically-beneficial shapes through multiple simulation iterations. Subsequently, the identified structures can be further validated and improved through rapid manufacturing using 3D printing for hardware evaluation in an anechoic chamber. However, to fully benefit from this emerging paradigm, an up-to-date survey of the most recent metal processes is required. This survey would determine which processes are well suited for building the next generation of antennas. For this purpose, a variety of metal 3D printing was employed to fabricate benchmark antennas with pathological geometries, including thin walls, overhanging features, and large aspect ratios. This survey can inform designers about potential structures to serve in novel antennas. A total of five processes have been preliminarily explored including selective laser melting, binder jetting, and plated vat photopolymerization, all of which delivered different advantages and disadvantages in terms of mechanical and electromagnetic performance.https://ieeexplore.ieee.org/document/8675738/3D printing3D printed antennas3D Hilbert curveadditive manufacturingantenna radiation patternbinder jetting |
collection |
DOAJ |
language |
English |
format |
Article |
sources |
DOAJ |
author |
Kerry Johnson Michael Zemba Brett P. Conner Jason Walker Edward Burden Kirk Rogers Kevin R. Cwiok Eric Macdonald Pedro Cortes |
spellingShingle |
Kerry Johnson Michael Zemba Brett P. Conner Jason Walker Edward Burden Kirk Rogers Kevin R. Cwiok Eric Macdonald Pedro Cortes Digital Manufacturing of Pathologically-Complex 3D Printed Antennas IEEE Access 3D printing 3D printed antennas 3D Hilbert curve additive manufacturing antenna radiation pattern binder jetting |
author_facet |
Kerry Johnson Michael Zemba Brett P. Conner Jason Walker Edward Burden Kirk Rogers Kevin R. Cwiok Eric Macdonald Pedro Cortes |
author_sort |
Kerry Johnson |
title |
Digital Manufacturing of Pathologically-Complex 3D Printed Antennas |
title_short |
Digital Manufacturing of Pathologically-Complex 3D Printed Antennas |
title_full |
Digital Manufacturing of Pathologically-Complex 3D Printed Antennas |
title_fullStr |
Digital Manufacturing of Pathologically-Complex 3D Printed Antennas |
title_full_unstemmed |
Digital Manufacturing of Pathologically-Complex 3D Printed Antennas |
title_sort |
digital manufacturing of pathologically-complex 3d printed antennas |
publisher |
IEEE |
series |
IEEE Access |
issn |
2169-3536 |
publishDate |
2019-01-01 |
description |
In the last decade, the proliferation of new 3D printing technologies has enabled the fabrication of complex geometries in manifold materials for novel applications. One discipline that has been explored extensively in the context of additive manufacturing is electromagnetic devices such as antennas. Difficult-to-fabricate geometries are now possible and can deliver new antenna functionality and extend performance (e.g., lower frequency resonance in small volumes, wider bandwidth, narrow-beam directionality, and so on). Coupled with accurate 3D electromagnetic simulations, a new paradigm is emerging for antenna design and manufacture. Starting from a seed geometry, the state space can now be explored to identify new combinations and permutations of electromagnetically-beneficial shapes through multiple simulation iterations. Subsequently, the identified structures can be further validated and improved through rapid manufacturing using 3D printing for hardware evaluation in an anechoic chamber. However, to fully benefit from this emerging paradigm, an up-to-date survey of the most recent metal processes is required. This survey would determine which processes are well suited for building the next generation of antennas. For this purpose, a variety of metal 3D printing was employed to fabricate benchmark antennas with pathological geometries, including thin walls, overhanging features, and large aspect ratios. This survey can inform designers about potential structures to serve in novel antennas. A total of five processes have been preliminarily explored including selective laser melting, binder jetting, and plated vat photopolymerization, all of which delivered different advantages and disadvantages in terms of mechanical and electromagnetic performance. |
topic |
3D printing 3D printed antennas 3D Hilbert curve additive manufacturing antenna radiation pattern binder jetting |
url |
https://ieeexplore.ieee.org/document/8675738/ |
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