Design and Manufacturing of a Hexapattern Frequency Selective Surface Absorber for Aerospace Stealth Application

Integrated frequency selective surface (IFSS) absorbers with larger bandwidth, effective reflection loss, polarization-insensitive characteristics, angular stability with compact/thin design, and ease of fabrication have captivated significant importance in stealth technology. Herein, we report on an IFSS absorber that has been designed, simulated, and implemented for manufacturing to achieve effective stealth properties. Initially, frequency selective surface (FSS) layers have been designed that comprise a closed centroid honeycomb structure surrounded with four annular hexagonal rings, splitted, alternatively, and enveloped with four L-shaped elements. The simulated pattern has been optimized on glass fabric for reflection loss (R_C, dB) at a thickness of ∼0.1 mm by choosing sheet resistance of pattern 110 Ω/□. A FSS layer combined with interlayer lossy dielectric laminates (1.8 mm) and a carbon-fabric-reinforced-plastic ground has been simulated as an IFSS absorber. The performance of R_C, in normal and angular configuration (0-60°), under transvers an electric/magnetic mode of polarization, including analysis of the displacement current, volume power loss distribution, and complex admittance has been carried on IFSS. Subsequently, the proposed absorber has been fabricated using customized carbon-based resistive ink imprinted on glass fabric by mask lithography compounded with laminates (a carbon black powder/epoxy composite) and ground. Their manufacturing details, including free space and anechoic chamber R_C measurements, have been presented. The simulated and experimental R_C performances of the absorber are found to be in good agreement, possessing minimal 10 dB reflection loss (90% absorption) with a sample thickness of 1.9 mm (0.05λ_L, where λ_L corresponds to a lower operating frequency), covering 76% fractional bandwidth in X and Ku bands. The proposed design architecture of the IFSS is ideally suitable for aerospace stealth platforms.