The Effect of Conductor Processing and Properties on Additively Manufactured Antenna Performance

Printed electronics techniques are increasingly utilized for device fabrication, particularly in flexible electronics. This study investigates the performance trade-offs associated with additive printed electronics methods and materials, focusing on antenna gain. A dual-band dipole antenna, operating at 2.4 GHz and 4.6 GHz, was designed using the ANSYS High-Frequency Structure Simulator (HFSS), with printed silver as the conductive material and 5mil (125 μm) Kapton as the substrate. Three sets of antennas, each with different conductive materials and printing techniques, were fabricated while maintaining a consistent substrate and antenna design. The fabrication techniques include dispensing and aerosol jet printing, with the conductive materials varying in particle size. Results show that resistance primarily affects antenna gain at 2.4 GHz, while the microstructure of the conductive material plays a more significant role at 4.6 GHz.