Abstract
This paper presents K-band-stepped, double-ridged square horn antennas fabricated by metallic 3D printing technology in copper (85% copper and 15% stannum) and aluminum alloy (89.5% aluminum, 10% silicon, and 0.5% magnesium). Compared with the popular dielectric 3D-printed horn antenna, the metallic counterpart features better mechanical robustness in terms of material. Moreover, the metallic horns are printed in one piece in one run, different from the dielectric horns that are printed in split pieces and electroplated, they simplify the process and thus result in reduced cost. The agreement between the simulation and measurement results verified the antenna’s performance. Both the 3D-printed copper and aluminum alloy antenna have an impedance bandwidth across the K-band, with a maximum gain of 13.23 dBi @ 25 GHz and 13.5 dBi @ 24 GHz, respectively. The metallic, 3D-printed horn antennas are preferable alternatives to replace traditionally-fabricated antennas.
Highlights
The 3D printing technology, invented in 1980s, is catching attention recently because of its eco-friendliness, short turn-around time and versatility with complex structures [1,2,3]
The weak mechanical robustness and the electrostatic discharge (ESD) from dielectric 3D printed parts are the major concerns under harsh circumstances
In this paper, taking advantage of an optimized 3D printing technology, we propose two K-band-stepped, double-ridged horn antennas in aluminum alloy (89.5% aluminum, 10% silicon, and 0.5% magnesium) and copper
Summary
The 3D printing technology, invented in 1980s, is catching attention recently because of its eco-friendliness, short turn-around time and versatility with complex structures [1,2,3]. Dielectric 3D printed parts usually bear low material and process costs. For the metallic 3D printed parts, the mechanical weakness and ESD might not be observed, while the heavy body mass and comparatively high material cost are not desirable. Timbie reported a dielectric 3D-printed, W-band (75–110 GHz) corrugated horn antenna, which was first printed in split pieces, metal plated and assembled [6]. Guo and Zhang pushed the upper limit of the metallic 3D printed horn antenna up to the H-band (220–325 GHz) [10,11,12] The aforementioned dielectric, 3D-printed, corrugated horn antennas are usually printed in split pieces, metal plated and assembled, which brings in complexities process-wise.
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