Investigation into applicability of 3D-printed composite polymers with enhanced mechanical properties in the development of microwave components

Additive manufacturing is currently regarded as one of the enabling technologies for Space Economy since it allows for the reduction of lead time and costs of payloads and platforms. Typically, metal-based additive manufacturing technologies are considered for the development of microwave components for Space applications since they exhibit the best trade-off in radio-frequency performance, benefits, and withstanding adverse environmental conditions. In this view, composite polymers may further increase the benefits arising from the 3D printing of microwave components since lighter parts with the required thermal, mechanical, and RF performances can be placed on board satellites. This paper explores the feasibility of 3D-printed composite polymers, including Ultem and PEEK reinforced with carbon fiber, for the development of microwave waveguide devices intended for Space applications. To this end, three different manufacturing routes were investigated by selecting a specific composite polymer, the corresponding manufacturing system and post-processing, and the necessary metal-plating technique. Hence, relevant radio-frequency test vehicles operating at 10 ÷ 14 GHz were designed, manufactured, and tested. The experimental results prove that waveguide components operating in X and Ku bands can be developed through the material extrusion of PEEK reinforced with carbon fiber, which is subsequently metalized by means of a two-stage electroless/electroplating process.