multimaterial additive manufacturing of ......novel additive manufacturing (am) methods • quad...
TRANSCRIPT
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UNCLASSIFIED 3D-PEIM, June 25th , 2018 UNCLASSIFIED
Multimaterial Additive Manufacturing of Radiofrequency Devices and Systems
Professor Mark S. Mirotznik Department of Electrical and Computer Engineering
University of Delaware
UNCLASSIFIED 3D-PEIM, June 25th , 2018 UNCLASSIFIED
State of the Art
What we want What we usually end up with
Multimaterial Additive Manufacturing of Radiofrequency Devices and Systems
The state of the art is somewhere in between, and isn’t necessarily applicable to large volume production.
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UNCLASSIFIED 3D-PEIM, June 25th , 2018 UNCLASSIFIED
Where is the application space for AM printed RF systems?
Multimaterial Additive Manufacturing of Radiofrequency Devices and Systems
1. Small Volume – Labor intensive parts or systems
UNCLASSIFIED 3D-PEIM, June 25th , 2018 UNCLASSIFIED
Where is the application space for AM printed RF systems?
2. Complex geometrical structures
Conformal RF electronics 3D Graded Material Properties
Multimaterial Additive Manufacturing of Radiofrequency Devices and Systems
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UNCLASSIFIED 3D-PEIM, June 25th , 2018 UNCLASSIFIED
Where is the application space for AM printed RF systems?3. Point-of-need manufacturing
Multimaterial Additive Manufacturing of Radiofrequency Devices and Systems
UNCLASSIFIED 3D-PEIM, June 25th , 2018 UNCLASSIFIED
What are the major challenges?
1. Materials – We think the development of new AM materials that possess good RF, mechanical, thermal, … properties is the biggest current challenge
Some Material Challenges(1) RF conductivities
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UNCLASSIFIED 3D-PEIM, June 25th , 2018 UNCLASSIFIED
What are the major challenges?
2. Multimaterial AM printing systems – For complex electronic systems moving parts between multiple printing systems is not ideal. Our goal is the print a part from start to finish on a single system.
Multimaterial Additive Manufacturing of Radiofrequency Devices and Systems
UNCLASSIFIED 3D-PEIM, June 25th , 2018 UNCLASSIFIED
What are the major challenges?
3. Quality control – AM systems typically run open loop often leading to failed parts (and sometimes failed printers).
Multimaterial Additive Manufacturing of Radiofrequency Devices and Systems
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UNCLASSIFIED 3D-PEIM, June 25th , 2018 UNCLASSIFIED
Material Development
q CNT based resistive inkq Magnetic inksq High permittivity inksq High conductivity inksq Quantum dot inks
Additive Manufacturing Methods
q Multi-material AM
q Structural composite integration
Multi-physics modeling and design of electromagnetically functionalized
structural composites
Applicationsq Graded Dielectrics
q Conformal load bearing antennas
q RF Antennas and Electronics
q Chemical sensing
Additive Manufacturing of Multifunctional RF Devices and Systems
UNCLASSIFIED 3D-PEIM, June 25th , 2018 UNCLASSIFIED
Additive Manufacturing of Multifunctional RF Devices and Systems
Novel Additive Manufacturing (AM) Methods
• Quad deposition heads• Material Agnostic via micro-
dispensing print heads• Prints viscosities from 1-1 million cp• Volumetric dispense control down
to 100 picoliters• Line sizes ~25-500 μm• Ability to print on conformal
surfaces via integrated laser scanning
• Ability to print thermoplastics (FDM)• Positional control down to 1μm
nScrypt 3Dn-300
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UNCLASSIFIED 3D-PEIM, June 25th , 2018 UNCLASSIFIED
Additive Manufacturing of Multifunctional RF Devices and Systems
Novel Additive Manufacturing (AM) Methods
UNCLASSIFIED 3D-PEIM, June 25th , 2018 UNCLASSIFIED
Material Development
q CNT based resistive inkq Magnetic inksq High permittivity inksq High conductivity inksq Quantum dot inks
Additive Manufacturing Methods
q Multi-material AM
q Structural composite integration
Multi-physics modeling and design of electromagnetically functionalized
structural composites
Applicationsq Graded Dielectrics
q Conformal load bearing antennas
q RF Antennas and Electronics
q Chemical sensing
Additive Manufacturing of Multifunctional RF Devices and Systems
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UNCLASSIFIED 3D-PEIM, June 25th , 2018 UNCLASSIFIED
Additive Manufacturing of Multifunctional RF Devices and Systems
Material Development: Inks and Pastes
Magnetically Loaded Inks High Permittivity Inks
Magnetodielectric Powder: Custom synthesized 20nm ferrite particles
+
Sample µr tanδm εr tanδeFe3O4 (10% vol.) 1.3 0.08 3.1 0.001Fe3O4 (20% vol.) 1.8 0.11 3.8 0.08Fe3O4 (30% vol.) 2.1 0.12 4.6 0.09Fe3O4/EPON (40% vol.) 2.4 0.13 6.2 0.11Ni0.5Zn0.5Fe2O4(20% vol.) 1.9 0.10 3.5 0.10Ni0.5Zn0.5Fe2O4 (30% vol.) 2.5 0.12 3.8 0.15
Barium Titanate Powder: 1-3 µm particle sizes
+
Polymer Resin and catalyst
Sampleµr tanδm εr tanδe
BaTiO3 (20% vol.) 1.0 0 9.6 0.006BaTiO3 (30% vol.) 1.0 0 16.7 0.02BaTiO3 (40% vol.) 1.0 0 23.0 0.03BaTiO3 (50% vol.) 1.0 0 36.8 0.04
* Measure from 16-27 GHz* Measure from 100-600 MHz
Polymer Resin and catalyst
UNCLASSIFIED 3D-PEIM, June 25th , 2018 UNCLASSIFIED
Material Development: Inks and PastesResistive Inks Metallic Inks
Carbon black powder
Polymer matrix
Carbon nanotubes
+
+
q Attractive EM loss propertiesq Nice viscosity for AM printingq Low costq No volatiles
Additive ManufacturingMaterial Development Effort
q Silver flakes + Silver nano-particlesq No organic binderq Potential for near bulk metallic propertiesq Been used for printable RF transmission lines and
antennasq Adjustable viscosities
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UNCLASSIFIED 3D-PEIM, June 25th , 2018 UNCLASSIFIED
Material Development: Inks and PastesFluorescent Inks
Additive ManufacturingMaterial Development Effort
q Quantum dots + hydrophilic resinq Design inks that adhere to a wide range of
surfaces: Clothing/Fabrics, Leather, Metal, Plasticsq Potential use for anti-tampering applications.
Under ambient lightThe printed array of squares is
largely transparent.Under UV light illuminationThe array of printed squares
are fluorescent.
Active Phase Changing Inks
Vanadium oxide (VO2)
0 10 20 30 40 50 60 70 80 900
50
100
150
200
250
300
350
400
450
Res
istiv
ity (
Ohm
s)
Time (seconds)
UNCLASSIFIED 3D-PEIM, June 25th , 2018 UNCLASSIFIED
Material Development: Inks and Pastes
Chemiresistive Inks
Additive ManufacturingMaterial Development Effort
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UNCLASSIFIED 3D-PEIM, June 25th , 2018 UNCLASSIFIED
Material Development: Custom Polymer Filaments
Additive ManufacturingMaterial Development Effort
Fused Deposition Modeling (FDM) extrudes melted thermoplastic filaments
UNCLASSIFIED 3D-PEIM, June 25th , 2018 UNCLASSIFIED
Material Development: Custom Polymer Filaments
Additive ManufacturingMaterial Development Effort
Polymer powder AdditivesCustom filaments
Print using FDM
ThermoFisher Process 11 Twin Screw Polymer Extruder
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UNCLASSIFIED 3D-PEIM, June 25th , 2018 UNCLASSIFIED
Material Development: Custom Polymer Filaments
Low Dielectric Constant Filaments (eer3.0)
Additive ManufacturingMaterial Development Effort
Barium Titanate Additivewithin a Polypropylene Matrix
At higher volume fractions of BaTithe filaments turn brittle
(consistency of hard spaghetti)
FDM printable**
*
* - measured data
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UNCLASSIFIED 3D-PEIM, June 25th , 2018 UNCLASSIFIED
Material Development: Custom Polymer FilamentsHigh Dielectric Constant Filaments (eer>3.0)
Additive ManufacturingMaterial Development Effort
UNCLASSIFIED 3D-PEIM, June 25th , 2018 UNCLASSIFIED
Material Development
q CNT based resistive inkq Magnetic inksq High permittivity inksq High conductivity inksq Quantum dot inks
Additive Manufacturing Methods
q Multi-material AM
q Structural composite integration
Multi-physics modeling and design of electromagnetically functionalized
structural composites
Applicationsq Graded Dielectrics
q Conformal load bearing antennas
q RF Antennas and Electronics
q Chemical sensing
Additive Manufacturing of Multifunctional RF Devices and Systems
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UNCLASSIFIED 3D-PEIM, June 25th , 2018 UNCLASSIFIED
RF Systems
Additive Manufacturing of Multifunctional RF Devices and Systems
UNCLASSIFIED 3D-PEIM, June 25th , 2018 UNCLASSIFIED
Additive Manufacturing of Multifunctional RF Devices and Systems
Printed Antennas
Conformal Antennas
q Ku-band 4 element patch arrayq The entire antenna was fully printed using the
nScrypt systemq Materials used were silver ink and polycarbonate
substrate
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UNCLASSIFIED 3D-PEIM, June 25th , 2018 UNCLASSIFIED
Additive Manufacturing of Multifunctional RF Devices and Systems
Printed Antennas
Conformal Antennas
q Ku-band 4 element patch arrayq The entire antenna was fully printed using the
nScrypt systemq Materials used were silver ink and polycarbonate
substrate
UNCLASSIFIED 3D-PEIM, June 25th , 2018 UNCLASSIFIED
Additive Manufacturing of Multifunctional RF Devices and Systems
Printed AntennasVery Small Antennas
Dielectric
Metal
Metal
Smallest feature size is 25 µµm
5mm
Fully 3D Printed Quadrupole Antenna
Designed by MITRE Corporation
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UNCLASSIFIED 3D-PEIM, June 25th , 2018 UNCLASSIFIED
Additive Manufacturing of Multifunctional RF Devices and Systems
Printed RF Transmission Lines
Grounded co-planar transmission line
50 mm
UNCLASSIFIED 3D-PEIM, June 25th , 2018 UNCLASSIFIED
Additive Manufacturing of Multifunctional RF
Devices and Systems
Printed RF Transmission Lines
Attenuation coefficient (dB/cm) f=12 GHz f=15 GHz f=18 GHz
Printed grounded co-planar waveguide 0.29 0.34 0.36
Printed microstrip transmission line 0.32 0.36 0.37
Transmission Coefficient
50 mm
Grounded co-planar
transmission line
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UNCLASSIFIED 3D-PEIM, June 25th , 2018 UNCLASSIFIED
Additive Manufacturing of Multifunctional RF Devices and Systems
Printed RF Connectors
12 13 14 15 16 17 18-50
-40
-30
-20
-10
0
Frequency (GHz)
S11 (
dB
)
Measured Return LossSimulated Return Loss
Edge Mount Connectors Return Loss
UNCLASSIFIED 3D-PEIM, June 25th , 2018 UNCLASSIFIED
Additive Manufacturing of Multifunctional RF Devices and Systems
Printed RF Connectors
12 13 14 15 16 17 18
-40
-30
-20
-10
0
Frequency (GHz)
S11
(dB
)
MeasuredSimulated
Face Mount ConnectorsReturn Loss
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UNCLASSIFIED 3D-PEIM, June 25th , 2018 UNCLASSIFIED
Additive Manufacturing of Multifunctional RF
Devices and Systems
Integration of Active Components
» Explore Automatic Placing Active Components:» Making Reliable Connections/Bonds
» Demonstrate Biasing Networks:» Push Pin Connections
» Explore Power Handling capabilities.
Avago AMMP-6408
6 to 18GHz 1W Power Amp
Printed
connectors
UNCLASSIFIED 3D-PEIM, June 25th , 2018 UNCLASSIFIED
Additive Manufacturing of Multifunctional RF Devices and Systems
Integration of Active Components
» Explore Automatic Placing Active Components:» Making Reliable
Connections/Bonds» Demonstrate Biasing
Networks:» Push Pin Connections
» Begin Exploring Power Handling capabilities.
Goals:
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UNCLASSIFIED 3D-PEIM, June 25th , 2018 UNCLASSIFIED
Material Development
q CNT based resistive inkq Magnetic inksq High permittivity inksq High conductivity inksq Quantum dot inks
Additive Manufacturing Methods
q Multi-material AM
q Structural composite integration
Multi-physics modeling and design of electromagnetically functionalized
structural composites
Applicationsq Graded Dielectrics
q Conformal load bearing antennas
q RF Antennas and Electronics
q Chemical sensing
Additive Manufacturing of Multifunctional RF Devices and Systems
UNCLASSIFIED 3D-PEIM, June 25th , 2018 UNCLASSIFIED
3D Printed Graded Dielectrics
34
Fabricate complex 3D geometries in which the electrical
properties (e.g. dielectric constant) vary nearly arbitrarily
in three dimensions
),,( zyxe
x
yz
Goal
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UNCLASSIFIED 3D-PEIM, June 25th , 2018 UNCLASSIFIED 35
( )2
2÷øö
çèæ+-=hhWhAcross p
hLAVF totcross×L×
= 2( )
L
+×÷ø
öçè
æ÷øö
çèæ --
=1
41 NhW
VF
p
micro-CT scan of printed space filling curve
Use of Space Filling Curves
3D Printed Graded Dielectrics
Volume fraction of printed material per unit cell
UNCLASSIFIED 3D-PEIM, June 25th , 2018 UNCLASSIFIED
Lens
Port 1 Antenna
Sample
RAMPort 2 Antenna
Lens
Use of Space Filling Curves: Dielectric Materials
3D Printed Graded Dielectrics
Material: Polycarbonate
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UNCLASSIFIED 3D-PEIM, June 25th , 2018 UNCLASSIFIED
Additive Manufacturing of Multifunctional RF Devices and Systems
Example Applications: Passive Beam Steering
Phased array technology is powerful but can be expensive and have limited operational bandwidths
Passive beam steering/switching can be a lower cost and wider bandwidth alternative to phased arrays.
UNCLASSIFIED 3D-PEIM, June 25th , 2018 UNCLASSIFIED
Additive Manufacturing of Multifunctional RF Devices and Systems
Example Applications: Luneburg Lens3D Luneburg Lens Beamformer
-r
0
r -r
0
r
-r
0
r
1
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
2
2
2)( ÷øö
çèæ-=Rrre
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UNCLASSIFIED 3D-PEIM, June 25th , 2018 UNCLASSIFIED
Additive Manufacturing of Multifunctional RF Devices and Systems
Modified Luneburg Lens
Quasi-Conformal Transformation Optics
det
Tee L L¢ =L
jjj
xx
¢¢ ¶L =
¶det
Tµµ L L¢ =L
UNCLASSIFIED 3D-PEIM, June 25th , 2018 UNCLASSIFIED
Additive Manufacturing of Multifunctional RF Devices and Systems
Modified Luneburg Lens
-r
0
r -r
0
r
-r
0
r
1
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
2
Quasi-Conformal Transformation Optics
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UNCLASSIFIED 3D-PEIM, June 25th , 2018 UNCLASSIFIED
Additive Manufacturing of Multifunctional RF Devices and Systems
Modified Luneburg LensQuasi-Conformal Transformation Optics
Fabricated Luneburg Lens using FDM Printing
Made from polycarbonate (eer=2.7)
UNCLASSIFIED 3D-PEIM, June 25th , 2018 UNCLASSIFIED
Additive Manufacturing of Multifunctional RF Devices and Systems
Example Applications: Luneburg Lens
Fabricated Luneburg Lens using 3D Printing
26-40 GHz
8-18 GHz
26-40 GHz
60-110 GHz
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UNCLASSIFIED 3D-PEIM, June 25th , 2018 UNCLASSIFIED
Additive Manufacturing of Multifunctional RF Devices and Systems
26 GHz
Modified Luneburg Lens (Ka-band 26 GHz – 40 GHz)
UNCLASSIFIED 3D-PEIM, June 25th , 2018 UNCLASSIFIED
Additive Manufacturing of Multifunctional RF Devices and Systems
W-Band Luneburg Lens (70-110 GHz)
Fabricated W-band Luneburg Lens using FDM printing with a 50 µµm
Human hair
25 µm nozzle
Z. Larimore, S. Jensen, A. Good, J. Suarez and M.S. Mirotznik, “Additive Manufacturing of Luneburg Lens Antennas Using Space-Filling Curves and Fused Filament Fabrication”, IEEE Transactions on Antennas and Propagation, May 2018.
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UNCLASSIFIED 3D-PEIM, June 25th , 2018 UNCLASSIFIED
Additive Manufacturing of Multifunctional RF Devices and Systems
W-Band Luneburg Lens (70-110 GHz)70 GHz
110 GHz
UNCLASSIFIED 3D-PEIM, June 25th , 2018 UNCLASSIFIED
Additive Manufacturing of Multifunctional RF Devices and Systems
Work in Progress: Luneburg Lens Array at 30 GHz
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UNCLASSIFIED 3D-PEIM, June 25th , 2018 UNCLASSIFIED
Material Development
q CNT based resistive inkq Magnetic inksq High permittivity inksq High conductivity inksq Quantum dot inks
Additive Manufacturing Methods
q Multi-material AM
q Structural composite integration
Multi-physics modeling and design of electromagnetically functionalized
structural composites
Applicationsq Graded Dielectrics
q Conformal load bearing antennas
q RF Antennas and Electronics
q Chemical sensing
Additive Manufacturing of Multifunctional RF Devices and Systems
UNCLASSIFIED 3D-PEIM, June 25th , 2018 UNCLASSIFIED
Additive Manufacturing of Multifunctional RF Devices and Systems
Example Applications: Chemical Sensors
Goal of this project to fabricate fully functional chemical sensors that can be integrated into conformal surface using multi-material/multi-functional additive manufacturing.
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UNCLASSIFIED 3D-PEIM, June 25th , 2018 UNCLASSIFIED
Additive Manufacturing of Multifunctional RF Devices and Systems
Example Applications: Chemical Sensors
Concept: Fully 3D integrated sensor for detection of multiple analytes
UNCLASSIFIED 3D-PEIM, June 25th , 2018 UNCLASSIFIED
Additive Manufacturing of Multifunctional RF Devices and Systems
Example Applications: Chemical SensorsMaterial Development
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UNCLASSIFIED 3D-PEIM, June 25th , 2018 UNCLASSIFIED
Additive Manufacturing of Multifunctional RF Devices and Systems
Example Applications: Chemical SensorsElectronics Integration
UNCLASSIFIED 3D-PEIM, June 25th , 2018 UNCLASSIFIED
Additive Manufacturing of Multifunctional RF Devices and Systems
Example Applications: Chemical SensorsAdditive Manufacturing
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UNCLASSIFIED 3D-PEIM, June 25th , 2018 UNCLASSIFIED
Additive Manufacturing of Multifunctional RF Devices and Systems
Example Applications: Chemical SensorsAdditive Manufacturing
UNCLASSIFIED 3D-PEIM, June 25th , 2018 UNCLASSIFIED
Questions/Acknowledgments
A PORTION OF THIS WORK WAS CARRIED OUT UNDER SBIR CONTRACT #W31P4Q-16-C-0110 IN
COLLABORATION WITH U.S. ARMY AMRDEC
THE AUTHORS WOULD LIKE TO ACKNOWLEDGE FUNDING SUPPORT FOR A
PORTION OF THIS WORK FROM THE OFFICE OF NAVAL RESEARCH.
Students and Collaborators:ØZach Larimore, Ph.D. candidate UDEL Dept. of ECEØPaul Parsons, Ph.D. candidate UDEL Dept. of ECEØAustin Good, Ph.D. candidate, UDEL Dept. of ECEØSarah Jensen, Ph.D candidate, UDEL Dept. of ECEØDr. Shridhar Yarlagadda, UDEL Center for Composite MaterialsØLarry “LJ” Holmes, Assistant Director of Additive Manufacturing, UDELØPaul Ransom, Ph.D., NSWCCDØJonathan Kruft, NSWCCDØDr. Peter Pa, Ph.D. UDEL Dept. of ECE (now at LEIDOS)ØMathew Mills, M.S. UDEL Dept. of ECE (now at NSWCCD)