Advanced additive manufacturing of 3D RF/microwave electronics based on novel electromagnetic nanocomposite materials
In recent years, several electromagnetic wave devices have been demonstrated by employing additive manufacturing (AM) technology, which makes the AM a great enabler for the next generation of RF and microwave devices. However, reported progress of RF materials compatible with fused deposition modeling (FDM) has been lacking, particularly to offer more options than the typical thermoplastics, such as acrylonitrile butadiene styrene (ABS), polyetherimide (PEI), and so on. The research objective of this proposal is to develop functional high-k and high- permeability electromagnetic composites of ultralow dielectric or magnetic losses, and their application to high-performance FDM manufactured microwave devices, such as antennas and filters, etc. The fabrication process employs a systematic approach for embedding sintered high-k fillers (e.g., MgCaTiO2, Ba0.55Sr0.45TiO3, and TiO2), or high-permeability fillers (e.g, Ba3Co2Fe24O41) into cyclo olefin polymer (COP) or other low-loss matrix. The proposed project also includes the evaluation of compatible metallization processes and the assessment of models for the prediction of the overall dielectric permittivity, magnetic permeability and their corresponding losses.