Printed Cylindrically Conformal RF Components and Embedded Electronics (1000-524)

SI2 Technologies, Inc. (SI2) proposes to develop a 3D printed embedded cylindrical Ka-band antenna with multi-layer printed transmission line feed network. The proposed program will provide a pathway to designing and easily fabricating low-SWAP-C multi-material AM antennas and other RF devices on the outside and inside of a cylindrical body with a 6-inch diameter. SI2 offers a unique combination of AM experience and RF design expertise for the development of cost-effective, 3D-printed antennas. In Phase I, prototypes of transmission lines will be printed onto the surface of a printed low-loss dielectric, such as Ultem, cylinder, and evaluated at Ka-band. SI2 will also print a 1x4 Ku-band (12-18 GHz) patch antenna onto a 6-inch diameter cylinder and test antenna the pattern at SI2’s nearfield range. Lessons learned from SI2’s Phase I process development effort will be applied in Phase II to the fabrication of an AM Ka-band (up to 35 GHz) antenna structure in a fully-automated process and in a single print. The printed prototypes will be environmentally tested, including shock, vibration, humidity, and temperature cycling. The prototypes will be tested to failure and the failure modes will be diagnosed.