Additive Manufacturing in Antenna Design: Evaluating Mechanical Resilience and Electromagnetic Efficiency Across Diverse Material Compositions

ABSTRACT In modern communication systems, antennas perform a pivotal role, serving as indispensable components across a diverse spectrum of applications, from underground and maritime communications to aerospace and military operations. The advent of additive manufacturing has brought significant changes to antenna fabrication, with techniques namely Fused Deposition Modeling (FDM), Stereolithography (SLA), and Direct Metal Laser Sintering (DMLS) at the forefront of producing lightweight yet robust and mechanically resilient structures. This comprehensive review elucidates the multifaceted classifications of antennas, delineating their mechanical designs and application‐specific frequency bands, whereas offering a nuanced comparative analysis of antennas fabricated using an array of materials, with particular emphasis on filament composition, operational frequency, and maximum realized gain. The study underscores the criticality of conductive coatings on dielectric filaments in achieving optimal radiation performance, thereby aligning additively manufactured antennas with the efficiency of their traditionally fabricated counterparts. Although the conclusions underscore the considerable potential of 3D printing in advancing antenna technology, they also acknowledge the necessity for continued research to overcome existing challenges and fully capitalize on the benefits of this innovative manufacturing method.