Self-Actuating 3D Printed Packaging for Deployable Antennas

In this paper we demonstrate the ability to use low-cost 3D printers to manufacture an ambulatory antenna at Ka bands with shape memory polymers to be used in an origami array. A focus on the manufacturing process and limitations is discussed. The antenna is metalized on the 3D printed dielectric substrate (polylactic acid) using direct print additive manufacturing to deposit a single part silver epoxy paste using a 152.4 μm syringe needle. After folding the substrate in a space saving state, a 60 °C heat source returns the shape memory polymer back to its printed permanently stored state. This demonstrates the possibilities of integrating shape memory polymers into packaging for the first time, while enabling future applications with heatsinks, origami meta-materials, and additional reactive and compact structures.