Design of high power microwave antennas using 3D printing technology

Complementary-split-ring (CSR) Slotted Waveguide Antennas have been proven to be critical to high-power-microwave (HPM) systems, due to their compact size, high gain and high power-handling capability. CSR-SWA designs depend on highly accurate electromagnetic simulations that take geometric details into full account. Conventional antenna manufacturing approaches such as direct machining and platelet technology lack the ability to precisely translate the electromagnetic simulation model into its physical metallization. To rapidly prototype complex 3D antenna structures in a cost-effective way, we propose an approach applying stereolithography or 3D printing technology. An S-band CSR-SWA printed on acrylonitrile butadiene styrene (ABS) and coated with metallic paint is tested. It is shown that 3D printing is capable of providing manufacturing precision for CSR-SWAs that makes fast prototyping of CSR-SWAs for HPM applications possible.