Conductive Electrifi and Nonconductive NinjaFlex Filaments based Flexible Microstrip Antenna for Changing Conformal Surface Applications

As the usage of wireless technology grows, it demands more complex architectures and conformal geometries, making the manufacturing of radio frequency (RF) systems challenging and expensive. The incorporation of emerging alternative manufacturing technologies, like additive manufacturing (AM), could consequently be a unique and cost-effective solution for flexible RF and microwave circuits and devices. This work presents manufacturing methodologies of 3D-printed conformal microstrip antennas made of a commercially available conductive filament, Electrifi, as the conductive trace on a commercially available nonconductive filament, NinjaFlex, as the substrate using the fused filament fabrication (FFF) method of AM technology. Additionally, a complete high frequency characterization of the prototyped antenna was studied and presented here through a comparative analysis between full-wave simulation and measurements in a fully calibrated anechoic chamber. The prototyped antenna measures 65.55 × 55.55 × 1.2 mm3 in size and the measured results show that the 3D-printed Electrifi based patch antenna achieved very good impedance matching at a resonant frequency of 2.4 GHz and a maximum antenna gain of −2.78 dBi. Finally, conformality performances of the developed antenna were demonstrated by placing the antenna prototype on five different cylindrical curved surfaces for possible implementation in flexible electronics, smart communications, and radar applications.