This Phase II SBIR research project will develop direct write copper conductors onto doubly curved dielectric substrates using the Kinetic Metallization (KM) process. There is a need for new processes and methodologies to enable low profile RF systems on current and planned airborne platforms. Low profiles antennas are achieved through integration with structural elements. The concept is referred to as aperstructures, and in this Phase II research the scientific and engineering foundation necessary for robust aperstructures will be laid. Principally, research to establish process-property relationships will be conducted, as well as an investigation of novel material systems. The envisioned result of this research is conformal antennas integrated into the load bearing structures of the application platform. Conformal antennas represent a significant stride forward in the ability to communicate in high bandwidth applications. They also offer lower profiles, lighter weight and greater mission flexibility.

Originally airborne platforms were identified as high benefit early adopters. Targeted markets in the Navy and Air Force have already been identified with customers awaiting the Phase II results to transition the KM process to the manufacture of antennas. Ship systems, land systems, and non-military opportunities such as automobiles and skyscrapers will also gain from the development of this research.

Project Report

New techniques for direct write fabrication of conformal antenna and RF systems were discovered and investigated through this NSF funded SBIR research project. Low-profile antennas integrated with structural elements on airborne platforms are referred to as aperstructures. Typically, these aperstructures are installed on doubly curved aircraft surfaces that require direct write methods to fabricated both the conductor and dielectric materials for these low-profile conformal antennas. Kinetic Metallization™ is a low temperature powder deposition process that permits the deposition of metallic and polymer composite coatings using feedstock powders. The small diameter profile of the Kinetic Metallization jet enables deposition of narrow-width metallic traces and antenna patches in a direct write fashion by using robotic translation of the nozzle in a prescribed pattern. Silver traces as small as 1-mm wide were deposited onto polymer composite dielectrics using an optimized Kinetic Metallization nozzle. Copper patches were also deposited onto doubly curved dielectric surfaces to demonstrate feasibility of fabricating conformal antenna systems with beam steering via time delay techniques. The most important discovery of this research was the direct write deposition of polymer-based dielectrics using the Kinetic Metallization process. Polymer powders including polyetherimide (Ultem®), polytetrafluoroethylene (Teflon®), or polyetheretherketone (PEEK) when blended with various oxide and ceramic powders permit deposition of dielectrics with tunable or variable dielectric constants. Dielectric constants were measured at 10 MHz to evaluate the prospects of tuning dielectric constants over a range of εr = 4 to 15. Future research with nanostructured multiferroic materials is expected to extend this range of dielectric constant values up to 500 for these polymer composites. Expanding this technology with other polymer and multiferroic materials will permit direct-write of various RF and sensor devices including phase shifters, magnetoelectric devices, and advanced ground planes for improving the gain of low profile antenna systems. Military and aerospace targeted markets have been identified with customers interested in the technology as a new tool for fabrication of conformal antennas. Ship systems, land systems, and non-military opportunities such as automobiles and infrastructures will also benefit from the successful accomplishments of this research.

Agency
National Science Foundation (NSF)
Institute
Division of Industrial Innovation and Partnerships (IIP)
Type
Standard Grant (Standard)
Application #
0724502
Program Officer
Muralidharan S. Nair
Project Start
Project End
Budget Start
2007-09-01
Budget End
2011-08-31
Support Year
Fiscal Year
2007
Total Cost
$546,255
Indirect Cost
Name
Innovative Technology, Inc.
Department
Type
DUNS #
City
Goleta
State
CA
Country
United States
Zip Code
93117