3D printed and circularly polarized 28 GHz patch antenna array for small satellite communications

This paper presents the design, fabrication, and testing of a high-gain compact 2 × 2 circularly polarized patch antenna array using 3D printing technology for small satellite 5G communication at 28 GHz. The proposed antenna demonstrates high efficiency and a low profile, addressing the limitations in design flexibility associated with traditional PCB fabrication methods. The 2 × 2 array configuration, incorporating via fences, coaxial vertical feedlines, and a sequentially rotated phased feed network, enhances the antenna's bandwidth and axial ratio bandwidth while maintaining compactness, crucial for space-constrained satellite applications. Simulations optimized key antenna parameters, including reflection coefficient, gain, and axial ratio. Measurement results validated the simulations, showing an impedance bandwidth of 6.8 GHz and an axial ratio bandwidth of 3.1 GHz, with a peak gain of 6.33 dB. Thermal cycling and electrical tests ensured the antenna's durability in space environments, demonstrating its potential for satellite use. These results indicate that 3D-printed antennas offer advantages in performance, cost, and manufacturing flexibility for satellite communication applications. • We developed a novel 3D printed patch antenna with enhanced gain and bandwidth. • An antenna demonstrated superior circular polarization characteristics across a wide frequency range. • A novel 3D printed patch antenna for 5G small satellite communications. • 3D printed materials validated about space environment evaluations.