?? 3D-Printed Patch Antennas with Copper Tape – A Simple & Effective Method!

I’ve developed a new method for fabricating patch antennas using 3D printing with dielectric materials such as PLA, PETG, or ABS, combined with copper tape. This approach makes antenna prototyping affordable, accessible, and highly customizable.

How It Works:

1?? Design & Simulation

• Model the antenna using simulation software (ADS, EMPro, CST studio, HFSS, ...).
• Determine the dielectric properties (relative permittivity & loss tangent) of your 3D-printed material. You can find these values in the literature or easily measure them using the T-line resonator method.
• Add a 0.1 mm raised layer on the substrate, matching the shape of the radiating patch and microstrip line. This will make it easier to apply the copper tape accurately.

2?? 3D Printing & Copper Layering

• Print the antenna structure.
• Apply a copper tape ground plane.
• Stick copper tape on the raised patch and microstrip, then cut it precisely with a scalpel.

3?? Final Assembly

• Solder the SMA connector, and your antenna is ready for testing!

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I designed and built a patch antenna for 5.2 GHz using the method described above, with PLA and copper tape.

The figure below shows a good agreement between simulation and measurement, validating the technique. The PLA and copper antenna achieves a gain of over 7 dBi at 5.2 GHz.This method greatly simplifies antenna fabrication and can be introduced in educational settings without requiring chemical or mechanical etching, which typically demands more resources. ????

What do you think about this approach? Let’s discuss in the comments! ??

Ref : https://edutice.hal.science/ENERGY-LAB/tel-04725201v1

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