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A 3D-printed broadband millimeter wave absorber.

Matthew Petroff1, John Appel1, Karwan Rostem2

  • 1Department of Physics and Astronomy, Johns Hopkins University, Baltimore, Maryland 21218, USA.

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|March 6, 2019
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Summary
This summary is machine-generated.

We developed a 3D-printed millimeter wave absorber using fused filament fabrication. This broadband absorber is designed for cosmic microwave background telescopes and survives cryogenic conditions.

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Area of Science:

  • Additive Manufacturing
  • Electromagnetics
  • Materials Science

Background:

  • Millimeter wave (mmWave) absorbers are crucial for reducing unwanted electromagnetic reflections.
  • Traditional absorbers can be bulky, expensive, and difficult to customize.
  • Applications in sensitive instruments like cosmic microwave background (CMB) telescopes require specialized, robust absorbers.

Purpose of the Study:

  • To design and characterize a novel 3D-printed broadband graded index millimeter wave absorber.
  • To optimize the absorber design for manufacturability using fused filament fabrication (FFF).
  • To evaluate the absorber's performance for applications in cryogenic environments, such as CMB telescopes.

Main Methods:

  • Additive manufacturing using a fused filament fabrication (FFF) 3D printer with a carbon-loaded high impact polystyrene filament.
  • Design optimization utilizing a space-filling curve to enhance manufacturability.
  • Electromagnetic characterization of the absorber's reflectivity from 63 GHz to 115 GHz and 140 GHz to 215 GHz.
  • Comparison of experimental reflectivity measurements with electromagnetic simulations.
  • Testing for survival of cryogenic thermal cycling.

Main Results:

  • Successful fabrication of a broadband graded index millimeter wave absorber via FFF 3D printing.
  • Measured reflectivity data aligns well with electromagnetic simulations across the specified frequency bands.
  • The 3D-printed absorber demonstrates performance suitable for terminating stray light in sensitive applications.
  • The absorber material and structure proved resilient to cryogenic thermal cycling.

Conclusions:

  • 3D printing offers a viable and customizable method for producing broadband millimeter wave absorbers.
  • The space-filling curve design strategy effectively enhances manufacturability for FFF.
  • The developed absorber meets key performance and environmental requirements for CMB telescope applications.
  • This technology advances the development of specialized electromagnetic components for scientific instrumentation.