Fabrication of conformal metasurface RF devices using 6-axis hybrid additive manufacturing

This research explores the feasibility to fabricate and characterize novel conformal metasurface antennas and radiofrequency (RF) filters developed using hybrid multi-material 6-axis additive manufacturing (AM). The interest to embed RF communication systems within structural components has been increasing for many defense and warfighter readiness applications such as integrating them within various platforms from aircrafts to naval ships. To accomplish this type of mission a blend of desired mechanical properties and electrical properties are needed. Conformal printing allows for optimal aerodynamic or hydrodynamic performance while also being able to functionalize this structural component as an active electronic device. This pushes the boundaries of AM and RF device manufacturing capabilities. AM is a rapidly growing technology that is more often being implemented because of its unique ability to create complex designs that conventional manufacturing methods are not capable of producing. AM traditionally has been used for prototyping and developing structures, however, to advance this technology, more functional and applicable AM prints need to be performed. Conformal 6-axis and hybrid multi-material AM would allow for growth in RF electronics and is a different type of fabrication method that is investigated here.