Layer-by-layer stereolithography of three-dimensional antennas

Horn antennas are created using laser-based layer-by-layer stereolithography processing in which three-dimensional structures can be synthesized directly from three-dimensional CAD files. The horns are used as a simple demonstration of how to create three-dimensional objects using rapidly deposited two-dimensional layers of polymer. Two types of horns are created using the polymer fabrication and then metallized using a conductive ink seed layer. This ink can be further metallized by the use of electroplating, however, the effects are shown to be minimal due to the small current density at all locations within the horn. Two types of horn operating in Ku band are realized to test the capability of this technique to create precise features without adversely affecting the pattern and the matching to the horn. The average return loss from the horns is above 20 dB throughout the band of operation and the measured gains (10.15 dB and 14.58 dB) are accurate within 5% with respect to the simulated values.