Indirect Applications of Additive Manufacturing for Antennas

We report the fabrication methodology of stereolithography (SLA) printed molds for metal and resin cast antennas. In the first method, a conical horn created using metal cast molds printed from a glass-filled resin utilizes a casting technique allowing for low-cost 3D printing to fabricate metal antennas, reducing the losses incurred by metallized plastics, while still producing complex geometries quickly. This metal cast conical horn is compared to a horn constructed using a more traditional 3D printing method. The second casting method demonstrates the interchangeability between creating parts via SLA printing with a glass-filled resin and using the same resin cast into a reusable Polydimethylsiloxane (PDMS) mold. We demonstrate this method by casting an interchangeable slug for a capacitively coupled, mechanically reconfigurable disk loaded monopole. Simulated and experimental data are presented for S textsubscript 11, and Gain. Simulated BW, directivity, gain and efficiency as a function of frequency are presented. The results indicate that the 3D printed metal casting process produces antennas with a higher gain and lower return loss than metallized resin antennas. The method is suitable for difficult geometries requiring resolution of at least $50 \mu \text{m}$ . The capacitively coupled disk loaded monopole demonstrates the versatility of 3D printing in antenna fabrication.