The US Naval Research Laboratory (NRL) experts created and tested 3D-printed antennas, arrays, and parts to advance radar technology at sea, improving its maritime navigation and national defense.
According to the NRL, the relatively low cost of 3D printing materials enable researchers to test multiple versions of parts at minimal overhead. The prototypes can then be machined using traditional methods.
“3D printing is a way to produce rapid prototypes and get through multiple design iterations very quickly, with minimal cost,” said NRL electrical engineer Anna Stumme. “The lightweight of the printed parts also allows us to take technology to new applications, where the heavyweight of solid metal parts used to restrict us.”
Now, Stumme and her colleagues are investigating how weight-and-size-constrained applications, such as unmanned aerial vehicles or small ships, can benefit from 3D-printed parts. Many of the 3D prototypes are printed using lightweight nylon in the Navy’s Laboratory for Autonomous Systems Research facility. Once the part is printed, it undergoes a process called electroplating.
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During the electroplating process, a thin coat of metal is applied to the printed part. Electroplating provides a conductive surface for the device to radiate as intended; something that isn’t feasible with plastic alone. The result is a lightweight prototype that can then be evaluated for a variety of attributes, such as surface roughness – a major factor in the functionality for antenna elements.
Following, Nick Charipar, head of the Applied Materials and Systems Section, adds that surface roughness plays a critical role for waveguides and antennas because it can cause scattering losses and result in a less efficient antenna, highlighting that “antennas radiate and receive waves. So if a wave runs along a rough surface it is distorted and the energy may not go where you want it to go.”
In the year following, Stumme and her colleagues aim to demonstrate new prototype cylindrical array apertures for an X-band surveillance radar demonstration in a laboratory setting. The X-band surveillance radar is designed to search the area surrounding a particular platform, such as a ship. They are exploring integrating cylindrical arrays into the masts of smaller vessels using microwave photonics and optical fibers.
Using optical fibers reduces the number of components required on a Navy ship’s mast, further reducing heat and weight constraints.
Concluding, it is reported that the demonstration will include testing traditionally manufactured and 3D printed versions of the array to compare performance. Stumme designed both versions.
