V-Band Monolithic Additive-Manufactured Geodesic Lens Array Antenna

Fully metallic geodesic lens antennas are popular for millimeter-wave band applications due to their simplicity, robustness, and low loss. Here, we report the experimental results of a geodesic lens array antenna, which was specifically designed to be additive-manufactured in one single piece using laser powder-bed fusion (LPBF). LPBF in aluminum alloy AlSi10Mg is able to produce high conductivity and relatively low surface roughness, so the antenna is highly directive and efficient. In addition, LPBF increases the robustness of the design since the lens array is monolithic, i.e., the risks associated with the assembly, including misalignments and undesired air gaps between pieces, are totally eliminated.