Low-cost and lightweight microwave antennas based on additive manufacturing

Additive manufacturing has become a transformative solution in telecommunications, enabling rapid and cost-effective prototyping of antennas and electronic components. This study presents the design, simulation, fabrication, and measurement of a bow-tie antenna optimized for operation in the S-band, using low-cost and easily accessible materials. Two versions of the antenna were developed, each employing a different conductive material: copper tape and low-cost conductive paint. Both designs were fabricated using a three-dimensional (3D)-printed plastic substrate, highlighting the potential for portable, field-ready antenna development. The performance of each antenna was evaluated through measurements and compared against simulated results. The analysis demonstrates that while copper tape offers reliable conductivity and consistent performance, the use of conductive paint may introduce limitations due to its lower electrical properties. These findings emphasize the importance of careful material selection in additive antenna manufacturing and offer a practical, adaptable solution for military telecommunications applications requiring fast deployment and minimal logistical overhead.