Abstract
Background: The purpose of this study was to determine if 3D printed lenses with wavelength specific anti-reflective (AR) surface structures would improve beam intensity and thus radar efficiency for a Printed Circuit Board (PCB)-based 60 GHz radar. This would have potential for improved low-cost radar lenses for the consumer product market. Methods: A hyperbolic lens was designed in 3D Computer Aided Design (CAD) software and was then modified with a wavelength specified AR structure. Electromagnetic computer simulation was performed on both the ‘smooth’ and ‘AR structure’ lenses and compared to actual 60 GHz radar measurements of 3D printed polylactic acid (PLA) lenses. Results: The simulation results showed an increase of 10% in signal intensity of the AR structure lens over the smooth lens. Actual measurement showed an 8% increase in signal of the AR structure lens over the smooth lens. Conclusions: Low cost and readily available Fused Filament Fabrication (FFF) 3D printing has been shown to be capable of printing an AR structure coated hyperbolic lens for millimeter wavelength radar applications. These 3D Printed AR structure lenses are effective in improving radar measurements over non-AR structure lenses.
Highlights
The research, development and application of radar with respect to the consumer market has greatly expanded over the last 10 years [1]
The material chosen for the 3D printing of the lenses was polylactic acid (PLA), that was shown in a previous investigation to have a relative permittivity of 2.74 at 60 GHz and a refractive index of 1.655 (n) at 60 GHz [13]
At the beginning of the evaluation of the smooth and AR structured lenses, a smooth lens was fixed within the holder and height alignment of the radar, lens and reflector was performed using a laser level
Summary
The research, development and application of radar with respect to the consumer market has greatly expanded over the last 10 years [1]. Due to the diverse setups, frequencies, geometries and subsequent focal point changes encountered in the consumer market, a new bespoke lens manufactured with a specific curve, radius and thickness is typically needed for each new product or situation Traditional techniques for this lens manufacture are often expensive due to the bespoke nature of the design, its complex geometry and a lack of off-the-shelf components. The purpose of this study was to determine if 3D printed lenses with wavelength specific anti-reflective (AR) surface structures would improve beam intensity and radar efficiency for a Printed Circuit Board (PCB)-based 60 GHz radar This would have potential for improved low-cost radar lenses for the consumer product market.
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