High-solid-content paste for stereolithography self-supporting printing of Luneburg lenses with a high degree of geometric-design freedom

Abstract

Luneburg lenses prepared by alumina stereolithography, have the advantages of low dielectric loss, corrosion resistance, and flexible structure. However, the supporting structure limits the degree of geometric design freedom. This paper analyzes the effects of modifiers and dispersants on paste properties from the molecular structure, which is different from the traditional process that doesn’t analyze the influence of similar mechanisms and binding site competition while ignoring the correlation. Based on the dispersant’s better flexibility bringing more obvious change in viscosity, we first determine the amount of dispersant and then adapt the amount of modifier to obtain self-supporting pastes of 82 wt % and 24.9 Pa.swithout gradation. The gain and beam deflection angle of Luneburg lenses with high geometric complexity and working bandwidth of 38° formed by stereolithography self-supporting process is matched to the simulation results without manufacturing defects, which provides a theoretical basis for more flexible design and manufacture of Luneburg lenses.