Additive Manufacturing of Conformal Microstrip Antenna Using Piezoelectric Nozzle Array

Abstract

Inkjet printing technology is widely used in the manufacture of conformal structures, such as load-bearing antennas or frequency-selective surface radomes. It is particularly promising for preparing conductive patterns on non-developable surfaces. Existing printing technologies employ a single nozzle and a five-axis linkage technique for printing, which is time-consuming. In this study, a conformal plane printing technology based on the arrayed nozzle was developed to prepare conductive patterns on a non-developable surface. The technique actualizes fast printing of passive circuits on a conformal surface, such as a microstrip antenna. Compared to printing techniques employing a single nozzle, the proposed method greatly improves the printing efficiency on conformal surfaces. Specifically, we first developed a model for the driver waveforms and the printing injection parameters via simulation. Subsequently, the accuracy of the computational fluid dynamic simulation results was validated by comparing them with the experimental measurements of droplet trajectory captured using a camera. Next, a droplet spreading model was established, considering energy conservation principles. Finally, a conformal surface printing technology using arrayed nozzles was developed based on the injection parameter and droplet spreading models. The effectiveness and feasibility of the proposed printing method were further validated via simulation and experimental tests of return loss.