Additive Manufacturing of a mmWave Microstrip Leaky Wave Antenna on Thin Alumina Substrate

This work demonstrates a novel process to fabricate a mmWave aerosol jet printed leaky wave antenna on an alumina substrate. While many variations of leaky wave antenna have been presented, most have been on conventional substrates such as FR4 or Rogers. Alumina presents an attractive alternative to these substrates due to its high thermal conductivity and high electric permittivity, as well as its durability and heat tolerance. By combining the advantages of the LWA design with the ideal properties of alumina substrate, a high-temperature capable steerable antenna is produced. Aerosol jet printing was used to realize this design without the need for vias. An aerosol jet printed leaky wave antenna is demonstrated for the first time, along with a sidewall patterning process using a 3D printed shadow mask. The design, manufacturing, and testing of the antenna are documented along with measured S-parameters. Applications include automotive radar and aerospace, where high performance and heat resistance are especially important.