Metal Additive Fabrication and Characterization of Horn Antenna

This paper presents a 3D printed rectangular horn antenna for 18 GHz to 26.5 GHz applications using 17-4PH stainless steel metal powder to demonstrate a powder bed fusion based Micro Laser Sintering (MLS) 3D printing technology. This technology allows manufacturing of metallic horn antennas at a lower cost and faster processing time than traditional high-cost fabrication processes. Also, MLS uses a finer metal powder that reduces component surface roughness, a significant downside of 3D printing technology. Furthermore, it can print a single-piece metal horn antenna, ensuring complete alignment and electrical compatibility between subcomponents and avoiding the need for any high-end post-processing steps before deployment. The claims made can be validated by the study of the effects of surface roughness on the gain, reflection coefficient, and transmission properties of the antenna. The findings for the two additively manufactured horn antennas (one polished and another as built) were compared to a standard one procured from Pasternack®.