Fabrication of <scp>3D</scp> Printable Low‐Loss, Dielectric‐Enhanced <scp>ABS</scp> – <scp>ZnO</scp> Nanocomposite Filaments for Microstrip Patch Antenna in <scp>GPS</scp> Communication

ABSTRACT Acrylonitrile butadiene styrene (ABS) is a key polymer used in fused filament fabrication (FFF) 3D printing; its limited electronic performance can be enhanced by incorporating suitable fillers. The current work presents ABS‐based nanocomposites infused with zinc oxide (ZnO) nanoparticles at concentrations of 5 and 10 wt. % and their filament preparation. Detailed assessments of the structural, morphological, thermal, mechanical, and dielectric characteristics of these composite filaments were carried out. The measured dielectric constant of 2.37 at 9.8085 GHz for pristine ABS was improved to 2.54 for 10 wt. % ZnO NPs nanocomposites‐based FFF printed sheet. At 1.575 GHz, it exhibited a quality factor of 18,587 GHz and loss tangent of 4.5 × 10 −3 , which were superior to the pristine ABS sample. A microstrip patch antenna operating at GPS frequency (1.575 GHz) was designed, simulated, and nanocomposite substrate was FFF 3D printed, followed by screen printing of patch and ground planes on it. The fabricated antenna achieved the resonance frequency of 1.592 GHz, with a voltage standing wave ratio (VSWR) value of 1.4211 and return loss of −15.222 dB and aligned closely with simulation predictions. The fabricated proof‐of‐concept (PoC) GPS module could continuously track its position, provide real‐time coordinates, and number of satellites detected. 3D‐printed specimens fabricated with optimized parameters exhibited superior tensile strength and thermal conductivity, elevated glass transition temperature (Tg), which ensured both mechanical robustness and thermal stability, making the ABS/ZnO nanocomposite substrate highly suitable for reliable microwave antenna performance.