3D Printed Linearly Polarized X-Band Conical Horn Antenna and Lens

A fast and convenient method to 3D print and metalize circular waveguide components is demonstrated using polylactic acid (PLA) and aluminum adhesive backed tape. A gradient index (GRIN) lens, an externally metalized thin-walled conical horn, and a WR90 rectangular to linearly polarized circular waveguide transition are simulated, fabricated, and measured. The horn and lens were both monolithic prints that were externally metallized to simplify the metallization process. Both the horn and lens have a measured operational bandwidth of 8.2 GHz to 12.4 GHz with an input reflection less than −15 dB and peak gain of 18.7 dBi at mid-band. The walls of the thin-wall horn are printed at a thickness such that the dielectric layer does not impact the performance of the horn while being robust enough to support external metallization. The lensed horn functioned as the support for the aluminum foil while also improving the radiation pattern by improving the $\vec {E}$ SLL by up to 15 dB compared to the thin-walled horn antenna.