3D-Printed Circular Horn Antenna with Dielectric Lens for Focused RF Energy Delivery

This paper presents the design, simulation, and fabrication of a horn antenna integrated with a dielectric lens for focusing RF energy at 10 GHz. The antenna system combines established electromagnetic principles with 3D printing techniques to produce a cost-effective alternative to commercial focusing antennas. The design methodology employs the lensmaker’s formula and Snell’s law to determine lens curvature for achieving a specified focal length of 100 mm. COMSOL Multiphysics simulations indicate that adding a PTFE lens increases power density concentration compared to a standard horn antenna, with a simulated focal point at approximately 100 mm. Surface roughness analysis based on the Rayleigh criterion supports 3D printing suitability for this application. Experimental validation includes radiation pattern measurements of the antenna without the lens and power density measurements versus distance with the lens, both showing good agreement with simulation results. The measured focal length was 95±5 mm, closely matching simulation predictions. This work presents an approach for implementing focused RF delivery solutions for medical treatments, wireless power transfer, and precision sensing at significantly lower costs than commercial alternatives.