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Related Experiment Video

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Indirect Fabrication of Lattice Metals with Thin Sections Using Centrifugal Casting
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3D Inductive Frequency Selective Structures Using Additive Manufacturing and Low-Cost Metallization.

Juan Andrés Vásquez-Peralvo1, Adrián Tamayo-Domínguez1, Gerardo Pérez-Palomino2

  • 1Radiation Group, Department of Signals, Systems and Radio Communications, Universidad Politécnica de Madrid, ETSI Telecomunicación, 28040 Madrid, Spain.

Sensors (Basel, Switzerland)
|January 22, 2022
PubMed
Summary
This summary is machine-generated.

Additive manufacturing enables low-cost prototyping of millimeter-wave frequency selective structures. Copper electroplating offers superior performance for complex designs compared to metallic paint atomization.

Keywords:
additive manufacturingfrequency selective structuresmetamaterials

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Area of Science:

  • Electromagnetics and Applied Physics
  • Additive Manufacturing and Materials Science

Background:

  • Additive manufacturing (AM) and metallization techniques are increasingly used for radio frequency (RF) components due to precision and cost-effectiveness.
  • AM is now accepted in demanding applications like satellite payloads and military systems.
  • A knowledge gap exists regarding the millimeter-wave frequency response of inductive 3D frequency selective structures (FSSs) fabricated with different metallization methods.

Purpose of the Study:

  • To design, simulate, and manufacture three dielectric 3D FSS prototypes for the millimeter-wave band.
  • To evaluate and compare the effectiveness of metallic paint atomization and electroplating for metallizing these structures.
  • To analyze the frequency response of the fabricated 3D FSSs before and after metallization.

Main Methods:

  • Three dielectric 3D FSS prototypes (square aperture, woodpile, torus) were fabricated using VAT photopolymerization.
  • Prototypes were metallized using nickel spray followed by copper electroplating.
  • Frequency response measurements were conducted using a measurement bench, and results were compared with CST Microwave Studio simulations.

Main Results:

  • Metallization resulted in a shifted and reduced band-pass response in some structures.
  • Copper electroplating yielded a band-pass with lower insertion loss for the complex torus structure.
  • The study provides a detailed table of metallization areas and applied currents for electroplating.

Conclusions:

  • Additive manufacturing combined with appropriate metallization is viable for producing millimeter-wave inductive 3D FSSs.
  • Copper electroplating is a more effective metallization technique for complex 3D FSSs in the millimeter-wave band, offering lower losses.
  • This research facilitates the low-cost manufacturing of advanced millimeter-wave components.