AM of RF Circuits

The Missile Defense Agency desires an additive manufacturing (AM) process for the fabrication of Radio Frequency (RF) antennas and wave guides on flexible substrates. In order to achieve this goal, it is needed to determine the signal loss of AM processed conductors relative to additively printed conductors. Further, the effects of voids in the AM conductors on the RF performance also needs to be investigated. Triton Systems proposes to characterize the performance and efficiency of AM conductors in the L, S, C, X, and Ku RF bands. During Phase I, Triton’s Team will produce RF test coupons of AM conductors on flexible substrate. The coupons will be evaluated over the RF bands and examined for void sizes and density arising during the AM process. An environmental test plan from -40°C to 125°C will be developed for execution during Phase II. Further, in Phase II, the void size and densities will be measured using a statistically significant set of samples. These samples will also be tested over the L, S, C, X, and Ku bands at 1W, 25W, and 50W. Approved for Public Release | 20-MDA-10643 (3 Dec 20)