DURIP Low-loss, Multi-material Dielectric Printer for Low-cost and High-performance Gradient-index (GRIN) Lens Antennas
Abstract
Publicly releasableProgram officer: Trevor SnowDirectorate: Code 312This DURIP proposal is for the purchase of 3D-printing equipment for the low-cost manufacture of low-lossdielectrics with permittivity ranging from 1.5 to 7.4, in support of PI Chisum#s current and pending researchfor ONR Code 312 under Dr. Trevor Snow (specifically, ONR contract #N00014-20-C-1067, entitled,#Co-designed Aperture and Feed GRIN Lenses for Low Scan-loss Beam-steering# and pending ONR SBIRproposal #N231-063-0537 entitled, #Advanced Hybrid Gradient Index Lenses via Additive Manufacturingof Low-Loss Materials#), as well as future related proposals planned for execution starting in FY24. Moregenerally, the requested equipment can print low-loss dielectrics (including ceramics) in arbitrary and conformalshapes and as such would also support packaging efforts in PI Fay#s current research for ONR Code 312under Dr. Paul Maki (specifically, ONR contract #N00014-20-1-2307-P00007, entitled #Advanced Designsfor GaN-based Vertical IMPATT Diodes#) and pending DARPA proposal entitled, #Rapid Development ofLow-Loss Graded Dielectrics via High-Throughput Combinatorial Printing and Machine Learning#.PI Chisum#s ONR-funded work on GRIN lens antennas has shown that wideband, large field-of-view(FoV) beam-scanning lens antennas are a potential low-cost replacement for phased array antenna (PAA),especially in high-effective isotropic radiated power (EIRP) applications.By using compound lens systemsthe lens can scan across a wide FoV with low scan loss. However, the complexity and cost of fabricatingGRIN lenses limits the number of prototypes that can be tested in a research program which ultimately slowsthe pace of innovation.And, to transition technology to industry the cost of manufacture must be low. Thisall requires a move to 3D-printed GRIN media where the printed dielectrics must be low-loss, provide a largepermittivity range, and be printed at low-cost.This DURIP proposes a dielectric printing system based upon the Fortify 3D FluxOne digital light projection(DLP) printer, in order to realize all three of the above requirements. Low-loss: Fortify has partneredwith Rogers Corp to develop the industries first low-loss photopolymer (RadixTM) for printed dielectrics.Large permittivity range: Permittivity is increased by filling a photopolymer with e.g., ceramic inclusionswhich also increases viscosity, causing prints to fail. However, using the proprietary Continuous Kinetic Mixing(CKM) technology, even viscous ceramic-filled photopolymer can be printed effectively, extending thepermittivity range while maintaining low loss. Low-cost: The proposed system is a DLP printer which usesparallel vat polymerization. Similar to other vat polymerization methods (e.g.,stereolithography (SLA)),DLP printers use light to cure a resin from a tank onto a build plate as it is pulled from the tank. However,in contrast to SLA, the DLP printer uses a high-resolution digital projector to #flash# an image and curean entire layer of the photopolymer at once. This inherent parallel process is key to low-cost manufacturebecause of the shorter lens print times.The proposed equipment will enhance the quality of $1.68M in current and $3.9M in pending DoDresearch. It will primarily allow for a more rapid prototype iteration cycle, owing to the lower cost of fabrication.Current lens fabrication methods combine subtractive manufacturing with extensive layer-by-layermanual assembly. This method is costly, time-consuming, and error prone. The proposed equipment willenhance the quality of research-related education because it will attract undergraduate students to the project.Professor Chisum regularly advises undergraduate students in research projects (for credit) on topics relatedto this proposal. It is expected that students will respond enthusiastically to the possibility of exploring 3Dprinting for antennas and packaging.
Document Details
- Document Type
- DoD Grant Award
- Publication Date
- Nov 08, 2024
- Source ID
- N000142412555
Entities
People
- Jonathan D Chisum
Organizations
- Office of Naval Research
- United States Navy
- University of Notre Dame