Analysis of 3D printed dielectric resonator antenna arrays for millimeter-wave 5G applications

This paper explores the potential use of fused deposition modeling (FDM) technology for manufacturing microwave and millimeter-wave dielectric resonator antennas (DRAs) for 5G and beyond communication systems. DRAs operating at microwave and millimeter-wave (mmWave) frequency bands were simulated, fabricated, and analyzed in terms of manufacturing quality and radio frequency (RF) performance. Samples were manufactured using a 3D printer and PREPERM® ABS1000 filament, which offers a stable dielectric constant (εr = 10 ± 0.35) and low losses (tan δ = 0.003) over wide frequency and temperature ranges. Surface profile tests and microscope measurements revealed discrepancies in the dimensions in the xy-plane and along the z-axis, consistent with the observed shift in resonant frequency. Despite these variations, reasonably good agreement between RF-simulated and measured results was achieved, and the DRA array successfully covered the intended mmWave band. However, challenges in achieving high precision may restrict applications at higher mmWave bands. Nevertheless, compared with conventional methods, FDM techniques offer a highly accessible and flexible solution with a wide range of materials for home and micro-manufacturing of mmWave DRAs for modern 5G systems.