Additive manufacturing of polymer composite millimeter‐wave components: Recent progress, novel applications, and challenges

Abstract With the advent of 5G/6G for radar and space communication systems, various millimeter‐wave (MMW) components are rapidly innovated for multi‐functional, higher integrated and miniaturized solutions across diverse industries and applications. Polymer composites‐based additive manufacturing (AM), an advanced manufacturing technique, can manufacture MMW components with high fabrication resolution, intricate structural design, adjustable dielectric properties, and functionally gradient distribution characteristics. This paper outlines the state‐of‐the‐art polymer composite MMW components, their design, and manufacturing techniques. An integrated “material‐structure‐manufacturing‐performance” design conceptual framework of polymer composite MMW components is discussed in terms of material design, structure design, and process design. Moreover, multi‐functional polymer composite MMW structures focus on electromagnetic wave absorption and electromagnetic interference (EMI) shielding functions. Moreover, novel applications of MMW polymer composite components enabled by AM on radar/sensing, communication, enclosure, and miscellaneous applications are discussed. Furthermore, future perspectives and current challenges are identified to provide new insights into multi‐functional 3D‐printed MMW products, exploring new possibilities for next‐generation advanced MMW technology. Highlights The 3D‐printed MMW components and additive manufacturing are reviewed. The integrated “material‐structure‐manufacturing‐performance” concept is introduced. 3D‐printed MMW components are discussed on radar, enclosure, and miscellaneous applications. Future perspectives and challenges of 3D‐printed MMW components are addressed.