Researchers have found a way to produce far smaller 3D-printed RF components.
Currently, there are limitations in 3D printing vertical structures with high aspect ratios. This geometry is often used for building RF components. As a result, the RF components tend to be larger than they could in theory be made.
The new approach is quite interesting and requires a couple of key steps.
They first 3D print the tiny structures using two-photon 3D printing (2PP). This creates the basic geometry at the desired small scale. However, 2PP produces parts made with resin that is not suitable for RF applications as it is not conductive.
The next step is to use electroplating to coat the tiny structures in conductive copper. A subsequent dry etching step removes the oxide layer on the surface outside the desired metal pattern.
The researchers tested this approach by creating split ring resonators (SRRs) as a test case. They found the method improves resonance frequency tuning, Q-factor improvement, and footprint miniaturization. This will allow for much smaller and more complex geometries.
They found that the Q-factor increased by up to 7X by raising the aspect ratio, something that could not be done with other approaches. They also found that the resonance frequency could be tuned by varying the metal thickness.
In all, they were able to reduce component footprint by a massive 45% while still maintaining the same performance, while operating in the 4-6 GHz frequency range.
However, they also found that the structures produced were quite fragile, and that’s not unexpected given the tiny size and high aspect ratios used.
The main outcome of this is that RF components could theoretically shrink significantly when used in a number of applications, such as wearables, IoT devices, biomedical sensors, and aerospace systems where weight is a concern.
The new method could also allow for higher-performing RF components that occupy the same space as current components. There is also the possibility of leveraging the technology to produce unusual RF geometries.
In the end, this could generate more RF application activity with 3D printing and drive up the use of 2PP systems.
Via Nature
