Laser Folded Antenna

A new hands-free approach to antenna fabrication is presented here, with laser folding used to fabricate a prototype 94.5 GHz end-fed longitudinal shunt slot array (EFLSSA) antenna. Laser cutting and folding was demonstrated for creation of 3D metal antennas as a low cost, rapidly iterated alternative to machining techniques such as electro-discharge machining (EDM) and die forming. The technique used is based on a low cost and power 1064nm marking laser. All cutting and folding is done completely remotely using the laser itself from a blank sheet of metal foil. The demonstrated waveguide slots are cut to sub-micron precision, and modelling of the resulting structure is also presented.