Abstract
This project has demonstrated feasibility of producing multi-layer RF and microwave frequency
components using aerosol jet additive manufacturing technology. The effort focused on novel stacked
component designs for devices such as antennas, electronic filters, resistive/inductive/capacitive (RLC) components, and transmission lines. Our approach to RF/microwave component fabrication by aerosol jet printing has the potential to reduce component size, improve performance characteristics, and allow devices to be fabricated on non-planar surfaces. Specifically, folded micro-patch antenna designs were fabricated by stacking layers of conductors and dielectrics printed in sequence using Optomec’s aerosol jet technology. ORNL supported the effort by providing design input on printing parameters and characterizing performance of printed structures. ORNL identified suitable stacked antenna designs, produced FEM models in HFFS, and provided the designs to Optomec for printing. After printing, the devices were tested and characterized at ORNL to determine frequency response and material characteristics of the printed components. These proof-of-principle devices will provide feedback on printing parameters, optimizations for the FEM models, and provide a path for more complex multi-layer device designs.