Selective Electron Beam Melting Manufacturing of Electrically Small Antennas

Real estate pressures in modern electronics have resulted in the need for electrically small antennas, which have subsequently garnered interest amongst researchers and industry alike. These antennas are characterized by their largest dimensions translating to a fraction of the operating wavelength; such a diminutive size comes at the expense of reduced gain and efficiency, and a worse overall match to a corresponding power source. In order to compensate for this deterioration in performance, antenna designers must turn towards increasingly complex and voluminous geometries, well beyond the capabilities of traditional manufacturing techniques. We present voluminous metal antennas, based on a novel inverted-F design, and fabricated using the emergent selective electron beam melting manufacturing technique, a type of powder bed fusion process. As predicted by small antenna theory, simulation results presented show in increase in the antenna’s efficiency as it is voluminously expanded into the third dimension. Measurement results illustrate that key trends observed from simulations are upheld; however, further understanding of the electromagnetic properties of raw materials, in particular how these change during the printing process, is needed. Nevertheless, this type of additive manufacturing technique is suitable for rapid prototyping of novel and complex antenna geometries, and is a promising avenue for further research and maturation.