Antenna device and method of manufacturing a cavity antenna

Abstract

An antenna device and a method of manufacturing a cavity antenna are disclosed. The antenna device (10, 110, 210) comprises a cavity structure (12, 113, 213) having a floor portion (20, 118, 218) and a peripheral wall portion (13, 116, 216) connected to the floor portion (20, 118, 218). A dipole structure (16, 117, 217) extends upwardly from a central region (137) of the floor portion (20, 118, 218) within the cavity structure (12, 113, 213). The peripheral wall portion (13, 116, 216) and the dipole structure (16, 117, 217) have at least one of an opening (15, 28, 127, 166, 227, 242) small enough relative to an intended radio frequency wavelength (24) to avoid affecting antenna performance.

Description

TECHNICAL FIELD

[0001] The present disclosure relates to systems and methods for wireless telecommunications. More particularly, the disclosed embodiments relate to antennas and antenna components. BACKGROUND

[0002] Antennas are a key element of wireless telecommunications technology for transmitting and / or receiving radio signals. The conductive material of an antenna serves as an interface between electrical current in a communicator circuit and radiated electromagnetic waves. The geometry and material of an antenna determine properties such as impedance, directivity, and bandwidth. Preferred properties depend on the intended location and application of the antenna, which can vary widely. For example, a user frequency modulation (FM) radio can use a monopole omnidirectional antenna suitable for receiving signals from any direction, while a global positioning system (GPS) satellite can use a highly directional antenna for globally directional transmission. For many applications, high-efficiency antennas must be produced with complex geometries built to high precision. Often, such antennas are manufactured through a slow and expensive process of manually assembling multiple individually machined parts.

[0003] Additive manufacturing (AM), sometimes referred to as 3D printing, is rapidly gaining popularity in many industries as a method for rapid production at relatively low cost. AM can be used to create a physical object from a 3D model by incrementally building up the object. Typically, AM applies a raw material that is then selectively joined or fused to create the desired object. Often, the raw material is applied in layers, where the thickness of each layer can depend on the particular technology used.

[0004] Typically, the raw material is in particulate or powder form, applied as a layer, and then selectively fused by a heat source. In many cases, the upper surface of a bed of such material is fused, and the growing workpiece is then lowered slightly. A new layer of raw material is then applied to the bed, and the next layer is fused into the previous layer. For example, the particulate raw material can include a thermoplastic polymer, a metal powder, a metal alloy powder, or a ceramic powder, which can be fused using a computer-controlled heat source such as a scanning laser or a scanning electron beam. Among other things, exemplary methods include selective laser melting (SLM), direct metal laser sintering (DMLS), selective laser sintering (SLS), fused deposition modeling (FDM), and electron beam melting (EBM).

[0005] Conventional part designs used for machining or other subtractive manufacturing can be inefficient or even non-functional for AM. Depending on the process and material used, unsupported features can collapse, proprietary features can be given insufficient clarity, and / or warping and cracking can occur. New designs are needed that maintain the functionality of conventional parts while enabling efficient use of AM methods.

[0006] US 2019-0291186 describes an additive manufacturing antenna apparatus including a base portion and a body portion. The body portion is attached to the base portion and includes a lattice stiffening structure configured to eliminate secondary print supports. SUMMARY

[0007] The present disclosure provides systems, apparatuses, and methods related to antenna apparatuses and components. In some embodiments, an antenna apparatus can include a cavity structure having a floor portion and a peripheral wall portion connected to the floor portion. A dipole structure can extend upwardly from a central region of the floor portion within the cavity structure. At least one of the peripheral wall and the dipole structure can have an opening that is sufficiently small relative to an expected radio frequency wavelength to avoid impacting antenna performance.

[0008] In some embodiments, an antenna apparatus can include an additive manufacturing cup structure and an additive manufacturing dipole structure. The cup structure can have a floor portion and a peripheral wall portion connected to the floor portion. The dipole structure can extend upwardly from the floor portion. At least one of the peripheral wall and the dipole structure can include an additive manufacturing mesh.

[0009] In some embodiments, a method of manufacturing a cavity antenna can include printing a cavity structure having a floor portion and a peripheral wall portion. The method can further include printing a dipole structure within the cavity structure. At least one of the cavity structure and the dipole structure can include a mesh.

[0010] The features, functions, and advantages described herein can be implemented independently in various embodiments of the present disclosure or can be carried out in conjunction with yet other embodiments. Further details of the present disclosure can be understood by referring to the following description and drawings. BRIEF DESCRIPTION OF DRAWINGS

[0011] Figure 1 is a schematic diagram of an illustrative antenna apparatus in accordance with aspects of the present disclosure.

[0012] Figure 2 is Figure 1 is a schematic diagram of a mesh of an antenna apparatus in

[0013] Figure 3 is an isometric view of an illustrative conventionally manufactured cup dipole antenna described herein.

[0014] Figure 4 is an isometric view of an illustrative additive manufactured cup dipole antenna in accordance with aspects of the present disclosure.

[0015] Figure 5 is Figure 4 is a cross-sectional isometric view of an antenna in

[0016] Figure 6is a cross-sectional view of the antenna along line 6-6 and further including a mounting attachment Figure 4 is a top view of the antenna in

[0017] Figure 7 is the cup dipole antenna described herein Figure 4 is a top view of the antenna in

[0018] Figure 8 is a top view of the antenna in Figure 4 is a top view of the antenna in

[0019] Figure 9 is an isometric view of another illustrative additively manufactured cup dipole antenna according to aspects of the present disclosure.

[0020] Figure 10 is a flowchart depicting steps of an illustrative method of additively manufacturing according to the present technology.

[0021] Figure 11 is a schematic diagram of an illustrative additively manufacturing apparatus described herein.

[0022] Figure 12 is a flowchart depicting steps of an illustrative method of additively manufacturing an antenna according to the present technology. DETAILED DESCRIPTION

[0023] Various aspects and embodiments of antenna components having cup-like structures, as well as methods of manufacture, are described below and illustrated in the associated drawings. Unless otherwise noted, the antenna components and / or various sub-components thereof can, but need not, include at least one of the structures, components, functions, and / or variations described, shown, and / or incorporated herein. Further, unless expressly excluded, process steps, structures, components, functions, and / or variations substantially or

[0024] This detailed description includes the following immediately preceeding sections: (1) Overview; (2) Embodiments, Components, and Alternatives; (3) Illustrative Combinations and Additional Embodiments; (4) Advantages, Features, and Benefits; and (5) Conclusion. The embodiments, components, and alternative portions are further divided into sub-sections A through D, with each sub-section being labeled accordingly.

[0025] Overview

[0026] Generally, an antenna apparatus or antenna component can include an additive manufactured structure. The antenna component can be configured to facilitate the transmission and / or reception of radio signals and can include a conductive material. The conductive material can include a portion or all of the additive manufactured structure and / or can be applied to the additive manufactured structure. The antenna component can be used as part of a conventional antenna such as a command horn, a cupped dipole, or a waveguide antenna, among others. Additionally or alternatively, the antenna component can be used as an antenna without additional components.

[0027] Figure 1 is a schematic view of an antenna component 10 represented in 10, having a cavity portion 12 with a peripheral wall 13 and a floor 20. The cavity portion can be described as tubular, cylindrical, and / or hollow. In Figure 1 the cavity portion 12 is described as having a circular cross-section, however, any suitable cross-sectional shape can be included. The cavity portion can be configured to form a channel or resonator for transmitting or receiving radio frequency signals and / or can be configured to guide radio frequency signals.

[0028] The antenna component 10 further includes an internal structure 16. The internal structure can have any geometric shape configured to facilitate the transmission and / or reception of radio frequency electromagnetic waves. The internal structure 16 can extend upward from the floor 20 and / or can be formed on other portions of the antenna component 10. For example, the internal structure can be a cross-dipole extending upward from a central region of the floor. The internal structure 16 can be configured for antenna properties of selective polarization, resonant frequency band, radiation pattern, and / or any function. The wall 13 can also have an internal geometry configured for antenna properties of selective polarization, resonant frequency band, radiation pattern, and / or any function.

[0029] The antenna component 10 includes a conductive material, which can be a laser sintered metal. In some embodiments, the component can include aluminum, copper, titanium, and / or alloys thereof. The component can include multiple materials or can be produced from a single material. In selecting a material or combination of materials for the antenna component 10, electrical conductivity, elasticity, density, and temperature sensitivity, among other factors, can be considered. The appropriate or desired material can depend on the intended application of the antenna component and the additive manufacturing method selected.

[0030] The antenna component 10 has a manufacturing orientation defined by a vertical axis 18, which can be parallel to a central axis of the cavity portion 12. In Figure 2 the vertical axis is described. The component can include multiple layers, generally each layer perpendicular to the vertical axis 18. Each layer can be thin and planar and fused or otherwise adhered to adjacent layers.

[0031] Changes from one layer to an adjacent layer can be limited. That is, the dimensions of the antenna component 10 can change gradually along the vertical axis 18. The antenna component can not include any abrupt protrusions, which can be described as any downward facing surface that forms an included angle with the vertical axis 18 that is greater than about 45 degrees or greater than about 50 degrees. Thus, all features of the antenna component 10 can be printed without the need for auxiliary support.

[0032] In some embodiments, the antenna component 10 can be post-processed from an additive manufacturing blank. Abrupt protrusions or other features that are not suitable for additive manufacturing can be machined. In this embodiment, the additive manufacturing blank can not include any abrupt protrusions and can be printed without the use of auxiliary support.

[0033] The thickness of the antenna component 10 can be limited for any structure. In other words, the thickness can have an upper and / or lower limit. For any structure, each layer in the antenna component can have a limited area. The limit can be absolute or relative. For example, the wall 13 of the cavity portion 12 can be limited to a thickness of less than 60 thousandths of an inch ("mil"), where 1 mil = 0.001 inches (""), or the wall 13 can be limited to 6% of the diameter of the cavity portion. Such a limit can prevent the printed material from cracking or tearing due to stresses introduced in the manufacturing process and / or subsequent cooling or other temperature fluctuations.

[0034] For another embodiment, the wall 13 can be limited to a thickness of greater than 20 mils. Such a limit can help to produce the desired printed resolution and features of sufficient strength to maintain geometric integrity through the additive manufacturing process.

[0035] As Figure 2 As schematically shown in FIG. 1, the perimeter wall 13 includes a mesh 14. The mesh can be described as including a plurality of holes or openings 15. The mesh can also be described as a regular array of openings, a lattice, and / or a first plurality of parallel linear structures intersecting a second plurality of parallel linear structures. In the described embodiment, the openings 15 are diamond shaped or triangular and are regularly spaced around the wall 13, which can help to maintain the circular shape of the cavity portion 12 through additive manufacturing of the antenna component 10. The mesh 14 can be configured to maintain any desired shape of the wall 13. The mesh 14 can also be configured to promote a stable geometry of the antenna component 10 and reduce warping and / or thermal distortion that occurs during the manufacturing process. Thus, the antenna component can have a lower geometric profile deviation from a computer aided design (CAD) standard specification.

[0036] The openings 15 can be shaped to allow for additive manufacturing of the mesh 14 without the use of auxiliary support. In the described embodiment, each edge of each diamond shape or triangular opening forms an included angle 17 with the vertical axis 18. The included angle 17 can be less than about 45 degrees or less than about 50 degrees. In other words, each linear structure defining an opening can form an included angle of less than about 45 degrees or less than about 50 degrees with the vertical axis 18.

[0037] Each opening 15 can have a maximum dimension 22. The maximum dimension can also be described as the maximum opening width of the opening. For the described diagonal openings, this dimension is between opposite corners. For circular openings, the maximum dimension would be the diameter of the circle. The antenna component 10 can be configured for transmitting and / or receiving radio signals in a range of wavelengths. In the described embodiment, the antenna component 10 is configured for transmitting and / or receiving radio signals in the range of 1-10 GHz. The radio waves are schematically depicted in Figure 2 The radio waves are schematically depicted in FIG. 1. The maximum dimension 22 of each opening 15 is limited relative to the smallest expected wavelength 24.

[0038] Limiting the maximum dimension 22 can ensure that the openings 15 have a negligible effect on the electromagnetic properties of the antenna component 10. For example, the maximum dimension 22 can be less than 10% of the wavelength 24. The maximum dimension 22 can be selected so that the effect of the openings 15 on the antenna component is below a selected acceptable threshold. The smaller the openings, the lower the effect of the openings can be, and the size of the openings 15 can be small enough relative to the expected wavelength 24 to avoid affecting antenna performance. In some embodiments, the maximum dimension can be less than 5% of the expected wavelength, or less than 2%.

[0039] The size and / or spacing of the openings 15 can also be determined according to the structural needs of the antenna component 10. That is, the openings 15 can be configured so that the mesh 14 has sufficient structural strength, rigidity, or other desired structural properties. In some embodiments, the base plate 20 can also include a mesh and / or openings.

[0040] Including the mesh 14 in the cavity portion 12 can reduce the overall volume of material used to additively manufacture the antenna component 10. This reduction can in turn reduce the material cost, manufacturing time, and weight of the component. The mesh 14 can also reduce the surface area of the cavity portion 12, thereby reducing the sensitivity of the antenna component 10 to vibrations and acoustic effects.

[0041] Additionally or alternatively, the internal structure 16 can include a mesh 26. The mesh can include one or more openings 28. Each opening can have a maximum dimension 30 that is limited with respect to the intended wavelength 24. Similar to the openings 15 detailed above, the openings 28 can be sufficiently small with respect to the intended wavelength such that the openings have a negligible effect on the electrical properties of the antenna component 10. The maximum dimension 30 can be different than the maximum dimension 22. The openings 28 can have a shape and / or pattern that matches or differs from the openings 15. The openings 28 can also be limited by the structural needs of the internal structure 16, particularly small or delicate structures such as dipoles.

[0042] In some embodiments, one or more portions of the antenna component 10 can be described as not being on the signal path of the antenna. The portion can include a mesh and / or openings that are any structurally appropriate configuration. That is, the size of the openings in the portion can be limited by structural considerations, rather than the intended wavelength.

[0043] The floor 20 of the cavity portion 12 or other portions of the antenna component 10 can be configured to connect to electronic circuitry. For example, the antenna component can include openings suitable for attaching a coaxial adapter. The antenna component can also be configured to connect to other antenna components such as a reflector dish or protective cover. In some embodiments, the antenna component 10 can be designed to have equivalent functionality to an existing antenna design and can be configured to connect to the common matching electrical system of the existing antenna design. For example, the antenna component 10 can be designed to have an impedance matching network to an existing conventional antenna design.

[0044] The antenna component 10 can be partially or entirely unitary. In other words, the walls 13, the mesh 14, the internal structure 16, the floor 20, and / or any other portions of the antenna component can include a single structure. The antenna component can be additively manufactured in one process without the need to assemble separate parts. The antenna component can also be manufactured without the need for auxiliary supports that are removed after manufacturing.

[0045] Due to the unitary construction, the antenna component 10 can have improved reliability. Failure modes related to the connection or interaction of parts can be eliminated. For example, the antenna component can not include bolts that loosen when vibrated, washers that shift under load, or tuning screws that change the tuning during shipping. In general, the likelihood of operational complexity can be reduced for an antenna that includes fewer parts.

[0046] The antenna component 10 can have a geometry that is configured to be repeatable. In other words, the geometry of the antenna component can be such that when multiple copies of the component are manufactured, each copy measures within a desired tolerance of the original design. In some embodiments, the desired tolerance can be 1 mil, can be 10 mils, or can be any suitable dimension. The manufactured copies can also be true to shape. For example, an opening designed to be circular can be consistently printed as a circle, rather than an ellipse.

[0047] Embodiments, components, and alternatives

[0048] The following sections describe exemplary antenna apparatuses and antenna components, as well as select aspects of related systems and / or methods. Embodiments in these sections are intended to be illustrative and should not be viewed as limiting the overall scope of the present disclosure. Each section can include one or more different embodiments, and / or contextual or related information, functionality, and / or structure.

[0049] A. Illustrative L-band cup dipole antenna

[0050] As shown in FIG. 1, this section describes an additive manufactured cup dipole antenna, generally indicated at 10. The antenna 10 includes an antenna frame 12 (i.e., an embodiment of the additive manufactured antenna component 10). The cup dipole antenna can also be described as a tunable antenna, or a cross-dipole antenna. Figures 4-8

[0051] A design of a conventional subtractive manufactured cup dipole antenna, generally indicated at 70, is shown. The conventional antenna 70 includes multiple separate machined components, each of which is bolted, glued, or otherwise affixed together. The antenna includes a generally cylindrical conductive cup 72 having a central opening. A dipole structure 74 is fastened within the cup 72 via the opening through a grommet. The dipole structure 74 includes two dipoles arranged perpendicular to each other: a long dipole 80 and a short dipole 82. The dipoles are mounted on a split-tube balun 84 (including a separate conductor 86 that must be mounted in the balun). The balun is configured to convert an unbalanced signal from a connected coaxial cable into a balanced signal of proper impedance. Figure 3

[0052] ​Long dipole 80 and short dipole 82 have lengths selected to tune antenna 70 to the selected frequency band and have appropriate relative lengths to achieve phase quadrature between the two dipoles. Thus, antenna 70 is circularly polarized. Cup 72 is configured to act as a resonant cavity and guide the radio frequency signal. The dimensions and positioning of each component of conventional antenna 70 are calculated to produce the desired functional properties of the antenna, such as polarization, resonant frequency, and directivity. However, some surfaces and structures of conventional antenna 70 are critical to the electromagnetic properties of the antenna, while other surfaces and structures are structurally and mechanically important.

[0053] By modifying key structural and machining features to achieve additive manufacturing, the additively manufactured antenna 110 can be configured to maintain key electromagnetic and functional characteristics of the conventional antenna 70. Antenna 110 can also modify key electromagnetic features, such as the length of the crossed dipoles, to maintain equivalent functionality despite structural changes such as changes in the reactance of the dipoles due to increased area.

[0054] like Figure 4 As shown in FIG, the antenna frame 112 of the antenna 110 is integral. That is, the antenna frame is a single component, reducing the overall assembly required for the antenna 110. The single component antenna frame 112 may also improve the reliability of the antenna 110 and / or reduce failure modes of the antenna.

[0055] The antenna is configured to be manufactured without auxiliary supports. In other words, after the antenna is manufactured, the support structure does not need to be removed. As described in more detail below, the described embodiment of the antenna frame 112 requires limited post-processing in the form of machining of detailed features such as the balun and bottom surface. The antenna can be configured so that the surface roughness resulting from manufacturing is sufficiently limited that full surface finishing is not required.

[0056] Antenna 110 can be configured to be manufactured using direct metal laser sintering (DMLS). The antenna comprises a sintered aluminum alloy, specifically, in this embodiment, AlSi10Mg Type II. Aluminum provides good strength, hardness, high load tolerance, and low weight. Any metal or alloy with similar properties can be used in any effective additive manufacturing process.

[0057] Antenna 110 is configured to perform radio communications within a frequency band. That is, the antenna is tuned to a range of radio frequencies. In the depicted embodiment, antenna 110 is tuned to the L-band, which includes wavelengths between approximately 11.8 inches and 5.9 inches (30 cm to 15 cm).

[0058] The antenna 110 includes an antenna frame 112 and a conductive core 114 (see Figure 6). The antenna frame 112 includes a cup 113 and an internal dipole structure 117, the cup including an outer wall 116 and a circular base 118. The cup 113 can constitute a circular aperture of the antenna 110. The cup can also be described as a tubular structure, and / or a hollow cylinder closed at one end.

[0059] The cup 113 can be about 7 inches in diameter, 7.5 inches in diameter, or 6 to 8 inches in diameter. The cup can be about 4 inches in height, about 4.5 inches in height, or 3 to 5 inches in height. The internal height of the cup 113 can correspond to the selected wavelength. The dimensions of the cup 113 can also be determined by the desired functional properties of the antenna 110.

[0060] The antenna frame 112 has a central axis 120 with the cup wall 116 centered thereon, which can be described as a manufacturing orientation of the antenna frame 112. When manufacturing the antenna frame, the central axis 120 can be parallel or perpendicular to the Z-axis of the manufacturing equipment. Accordingly, the antenna frame 112 can include a plurality of planar layers perpendicular to the central axis 120.

[0061] The cup wall 116 is primarily composed of a mesh 124, which includes a plurality of openings 127. The mesh can also be described as a lattice structure, a framework, and / or a plurality of holes in the wall 116. In some embodiments, the cup base 118 can also be partially or entirely composed of a mesh.

[0062] The openings 127 include a diamond shape and a half-diamond or triangular shape. In some embodiments, the openings can include a polygonal shape or a self-supporting non-polygonal shape such as a teardrop shape. As described above, the mesh 124 is an embodiment of the mesh 14. The openings 127 are regularly spaced apart and oriented around the wall 116 such that the sides of the aperture form an included angle with the central axis 120 of no more than about 45 degrees. The openings 127 can also be described as being defined between a plurality of intersecting linear structures, each of which forms an included angle with the central axis 120 of no more than about 45 degrees. In embodiments where the cup base 118 includes a mesh, the openings of the mesh can not be constrained to a polygonal shape and / or an included angle with respect to the central axis due to the orientation of the cup base 118 being perpendicular to the manufacturing orientation of the antenna frame.

[0063] The thickness of the mesh 124 (which can also be referred to as the thickness of the wall 116) can be about 45 mils, can be between 40 and 50 mils, or can be between 20 and 60 mils. In particular embodiments, the mesh has a thickness between 20 mils (0.508 mm) and 120 mils (3.048 mm). The diamond shape and regular pattern of the openings 127 can reinforce and strengthen the thin outer wall, improving structural strength. The shape and pattern of the openings can also be configured to maintain the circular shape of the cup 113 and, in turn, the circularity of the aperture of the antenna 110.

[0064] The opening 127 can be sized to ensure that the effect on the antenna's electrodynamic properties is negligible. In other words, the opening 127 can be sized to be sufficiently small relative to the expected wavelength to avoid affecting antenna performance. In some embodiments, the maximum dimension of the opening can be selected so that changes in antenna properties such as gain are below a selected acceptable threshold.

[0065] The size, shape, spacing, and / or arrangement of the openings 127 may also be determined based on the structural requirements of the antenna assembly 10. That is, the openings 127 may be configured to provide the mesh 124 with sufficient structural strength, rigidity, or other desired structural properties.

[0066] In the depicted embodiment, the cup wall 116 is divided into an upper mesh portion 126 and a lower mesh portion 128 separated by a cover coupling ring 130. The cover coupling ring 130 is a smooth surface without openings and has an equal or greater thickness than the mesh 124. The bottom edge of the ring can be chamfered at an angle of approximately 45 degrees. The smooth surface of the cover coupling ring 130 can be configured for effective adhesion of an adhesive. In some embodiments, the ring can include recesses, grooves, or other features configured to facilitate connection to the antenna cover.

[0067] like Figure 5 As more clearly shown in FIG, the dipole structure 117 of the antenna frame 112 includes a long dipole 138 and a short dipole 140, each connected to a balun tube 136. The balun tube 136 is a cylinder with an octagonal flange 142 at its top end. The balun tube is hollow, with a central circular cavity aligned with the central circular hole of the cup base 118. The balun tube 136 extends upward from a central region 137 of the cup base 118 and is joined to the cup base. The balun tube can also be described as being centered on or coaxial with the central axis 120 of the antenna frame 112. The octagonal flange 142 can be chamfered and / or rounded so that the flange does not extend perpendicularly outward from the outer surface of the balun tube 136. In the depicted embodiment, the octagonal flange 142 is beveled at approximately 45 degrees to the outer surface of the balun tube 136.

[0068] Long dipole 138 includes a first pole 138A and a second pole 138B, each of which is planar or sheet-shaped and extends from balun tube 136. Short dipole 140 includes a first pole 140A and a second pole 140B, each of which is planar or sheet-shaped and extends from balun tube 136. First pole 138A and second pole 138B are parallel, coplanar, coextensive, and have matching dimensions. Similarly, first pole 140A and second pole 140B are parallel, coplanar, and coextensive, but have different dimensions. In the depicted embodiment, all four poles have matching thicknesses. Each pole in long dipole 138 is perpendicular to each pole in short dipole 140.

[0069] Each pole 138A, 138B, 140A, 140B has a generally triangular shape with square outer corners. The length of the poles can be selected to achieve a desired phase difference between the signal of the long dipole 138 and the short dipole 140. Specifically, the length can be selected to achieve phase quadrature and thereby circular polarization of the antenna 110.

[0070] Each pole 138A, 138B, 140A, 140B includes a mesh 164. The mesh of the poles includes a plurality of holes or openings 166. Similar to the openings 127 of the mesh 124 described above, the openings 166 are also sized for the antenna 110 to operate within the L-band of radio frequencies.

[0071] However, if Figure 5 As shown in FIG, openings 166 have a different size and shape than openings 127 of mesh 124. More specifically, openings 166 have a square shape and measure approximately one-tenth of an inch diagonally. The size of openings 166 is determined based on the structural requirements of dipoles 138, 140. Since a dipole is a smaller structure than cup wall 116, mesh 164 is thinned to maintain the structural strength of the dipole. That is, openings 166 of mesh 164 are configured to provide sufficient structural strength and rigidity to internal dipole structure 117.

[0072] The balun tube 136 is configured to act as a split-sheath balun in cooperation with the conductive core of the antenna and convert an unbalanced signal from the connected coaxial cable into a balanced signal of appropriate impedance. Figure 8As shown in FIG. 1 1, two slots 148 extend vertically down from the octagonal flange 142 through the balun tube 136 toward the cup base 1 18. The slots 148 can have a length that is less than the length of the balun tube 136, and the upper portion of the balun tube can be split by the slots. The length of the slots 148 can be selected to match the reactance of the dipoles 138, 140. The slot length can also be proportional to or correspond to the selected wavelength. In some embodiments, the slots 148 can extend the overall height of the balun tube 136, and the tube can comprise two separate structures, each joined to the cup base 1 18.

[0073] The octagonal flange 142 is divided into an unconnected portion 142A and a connected portion 142B. The dipoles 138A and 140A are joined to the unconnected portion 142A, while the dipoles 138B and 140B are joined to the connected portion 142B. As shown in FIG. 1 1, the unconnected portion 142A is not in contact with the conductive magnetic core 1 14 when the core is installed in the antenna frame 1 12, and the core is secured to the connected portion 142B by the tab 150. Figure 6

[0074] The core tab 150 rests in a recess 151 of the connected portion 142B of the octagonal flange, as shown in FIG. 1 1, i.e., shaped to snugly receive the tab. A hole in the core tab is aligned with a threaded hole in the recess 151 configured to receive a fastener. Thus, the conductive magnetic core can be mechanically secured to the antenna frame 1 12 by the fastener. In some embodiments, the core tab can be glued or otherwise attached to the antenna frame 1 12. Figure 4

[0075] As shown in FIG. 1 1, the conductive magnetic core 1 14 extends down from the core tab 150 through the hollow interior of the balun tube 136 without contacting the tube. The conductive magnetic core 1 14 can also be connected to the antenna frame 1 12 in any electrically equivalent and effective manner. The conductive magnetic core and the antenna frame 1 12 can be manufactured separately, and the conductive magnetic core can be conventionally or additively manufactured. The conductive magnetic core 1 14 can comprise the same material as the antenna frame 1 12, can comprise the same aluminum alloy, or can comprise any suitable electrically conductive material. Figure 6

[0076] In FIG. 1 1, the antenna 1 10 is shown in an installed configuration, including a mounting bracket 152 and a sunshade 154. The sunshade 154 extends above the open end of the cup 1 13 and is configured to shield the antenna 1 10 from solar radiation. The sunshade is glued to the cap coupling ring 130. The sunshade 154 can comprise an insulating and / or light-reflecting material and can be manufactured separately from the antenna 1 10. Figure 6

[0077] ​​​​Mounting bracket 152 can be part of the structure to which antenna 110 is mounted or secured to the structure to which antenna 110 is mounted. For example, mounting bracket 152 can form part of a housing of a communications satellite. Cup base 118 includes fastener holes configured to attach to mounting bracket 152. In this embodiment, cup base 118 includes four fastening / fastener holes 156, which can be more clearly seen in Figure 5 Fastener holes 156 align with corresponding holes on mounting bracket 152 to receive fasteners, not shown. Cup base 118 or other components of antenna 110 can include any features configured to attach antenna 110 to mounting bracket 152 and / or other structures.

[0078] Figure 6 Further described is coaxial connector 158 extending through the center hole of cup base 118 into balun tube 136. The connector is configured to interface with conductive magnetic core 114 at a first end and a coaxial cable at a second end. Any effective connector can be used. In this embodiment, a pin of the connector is threaded into a recess of conductive magnetic core 114. Coaxial connector 158 is also supported by interfacing with cup base 118 and balun tube 136. In this embodiment, the inner surfaces of balun tube 136 and cup base 118 are threaded and threadingly engage on connector 158. In some embodiments, connector 158 can be glued to cup base 118 or can be secured in any effective manner.

[0079] Figure 7 is a top view of an embodiment of an additively manufactured blank 160 of antenna frame 112. As Figure 8 shown in , the blank can be machined, drilled, or otherwise post-processed to produce antenna frame 112. Features of antenna frame 112 included in the blank can be referred to as printed features, and features produced during post-processing can be referred to as finish features.

[0080] Figure 7 As shown in Figure 8 , blank 160 includes a solid center magnetic core 162. Dipole 138, 140 and beveled octagonal flange 142 are printed features, while features of balun tube 136 are finish features. In other words, solid magnetic core 162 is machined to produce balun tube 136 shown in above and

[0081] . Solid magnetic core 162 is hollowed out and slots 148 are cut. Balun tube 136 can also be threaded near the bottom end of cup base 118. Recess 151 is machined into octagonal flange 142, and threaded holes are drilled and tapped into the recess.The cup base 118 is printed as a solid structure with a flat surface. The center hole and fastener holes 156 of the cup base 118 are drilled through the cup base. Either or both of the center hole and fastener holes can also be tapped to produce threads. The cup base can be printed approximately 50 mils thicker than required for the antenna frame 112. This material allows the printed body to be machined into a printer base or support plate. A pattern of recesses, such as a wagon wheel shape, can also be machined into the bottom surface of the cup base 118. The recesses can be used to reduce the weight of the antenna frame 112 while maintaining and / or improving the structural properties of the cup base 118, such as stiffness and strength.

[0082] The web 124 of the cup wall 116 and the web 164 of the dipoles 138, 140 are printed features of the blank 160. That is, the blank 160 includes openings 127, 166. The openings do not need to be machined into the cup wall or the dipoles, and the webs 124, 164 can remain in the printed state without machining or other post-processing.

[0083] Figure 4 and Figure 5 The cover coupling ring 130 of the cup wall 116 shown in FIG can be machined to create a smooth surface suitable for bonding. The printed ring can include an additional 50 mils of material to be machined. Due to the cup printing, the cover coupling ring can be raised 70 mils relative to the mesh 124. After machining, the ring can remain raised 10 mils relative to the mesh. This distance protects the mesh 124 during the machining process and prevents undesirable changes to the mesh. Machining the cover coupling ring 130 creates a smooth surface that facilitates bonding of the parasol described above.

[0084] B. Illustrative S-band cup dipole antenna

[0085] like Figure 9 , which depicts an additively manufactured cup dipole antenna, generally designated 210. As described above, antenna 210 includes antenna frame 212, an embodiment of additively manufactured antenna component 10. The cup dipole antenna may also be described as a tunable antenna, or a cross-dipole antenna.

[0086] Antenna 210 is configured to perform radio communications within a frequency band. That is, the antenna is tuned to a range of radio frequencies. In this embodiment, antenna 210 is tuned to the S-band, which includes wavelengths of approximately 5.9 inches to 2.95 inches (15 cm to 7.5 cm).

[0087] The antenna frame 212 includes a cup 213 and an internal dipole structure 217, the cup including an outer wall 216 and a base 218. The wall 216 encloses a circular area of the base 218, and the cup 213 can form a circular radiating aperture of the antenna 210. The cup can also be described as a tubular structure, and / or a hollow cylinder closed at one end. The base 218 can be shaped to facilitate connection of the antenna 210 to a mounting structure.

[0088] The cup 213 can be about 4 inches in diameter, 4.5 inches in diameter, or 3 to 5 inches in diameter. The cup can be about 2 inches in height, about 2.5 inches in height, or 1 to 3 inches in height. The internal height of the cup 213 can correspond to a selected wavelength. The dimensions of the cup 213 can also be judged by the desired functional properties of the antenna 210.

[0089] The antenna frame 212 has a central axis 220 centered in the middle of the closed circular portion of the cup wall 216 and the base 218. The central axis 220 can be described as a reference for orientation of the antenna frame 212. When the antenna frame is manufactured, the central axis 220 can be parallel to a vertical axis or z-axis of the manufacturing equipment. Thus, the antenna frame 212 can include a plurality of planar layers perpendicular to the central axis 220.

[0090] The cup wall 216 is entirely composed of a mesh 224, the mesh 224 including a plurality of openings 227. The mesh can also be described as a lattice structure, a framework, and / or a plurality of openings in the wall 216. The openings 227 include a diamond shape and a half-diamond or triangular shape. The mesh 224 is an embodiment of the mesh 14 described above. The openings 227 are regularly spaced around the wall 216 and positioned such that sides of the openings form an included angle with the central axis 220 of no more than about 45 degrees. The openings 227 can also be described as being defined between a plurality of intersecting linear structures, each linear structure forming an included angle with the central axis 220 of no more than about 45 degrees.

[0091] The thickness of the mesh 224 (which can also be referred to as the thickness of the wall 216) can be about 45 mils, can be between 40 mils and 50 mils, or can be between 20 mils and 60 mils. The diamond shape and regular pattern of the openings 227 can reinforce and strengthen the thin outer wall, improving structural strength. The shape and pattern of the openings can also be configured to maintain the circular shape of the cup 213 and, in turn, the circularity of the aperture of the antenna 210.

[0092] The openings 227 can be sized to ensure negligible impact on the electrical properties of the antenna. In other words, the openings 227 can be sized to be sufficiently small relative to the intended wavelength to avoid impacting antenna performance. In some embodiments, the largest dimension of the openings can be selected such that changes in properties of the antenna, such as gain, are below a selected acceptable threshold.

[0093] The size, shape, spacing, and / or arrangement of the openings 227 can be determined according to the structural needs of the antenna component 210. That is, the openings 227 can be configured such that the mesh 224 has sufficient structural strength, rigidity, or other desired structural properties.

[0094] The dipole structure 217 includes four poles 236 extending from a cylindrical support 238. The cylindrical support can include unshown connection features to allow the feed line to be operatively connected to the antenna. Each pole 236 includes an independent vertical support having a triangular protrusion 240 extending from the central axis 220. The lower or overhanging surface of each protrusion 240 forms an included angle of about 45 degrees or less with respect to the central axis 220. Thus, the dipole structure 217 can be printed without the use of auxiliary supports.

[0095] The four poles 236 include two pairs of poles, each pair of poles having protrusions 240 extending in opposite parallel directions, and each pair of protrusions extending orthogonally with respect to the other pair of protrusions. Each pair of poles is configured to act as a dipole such that the dipole structure 217 acts as a cross or tunable dipole antenna.

[0096] Each triangular protrusion 240 includes a triangular opening 242. Like the protrusions 240, the openings 242 are positioned such that any side of the opening does not form an included angle greater than about 45 degrees with respect to the central axis 220. In sum, the openings 242 can be described as a mesh. The openings 242 can reduce the material volume and / or weight of the dipole structure 217 without significantly affecting the electrical properties of the poles 236.

[0097] In the present embodiment, the openings 242 can be described as being located outside of the signal or radio frequency path of the antenna 210. Thus, the size and shape of the openings can be constrained by the structural properties of the poles 236, rather than the wavelength of the intended radio signals. In some embodiments, the openings of a dipole structure, such as the antenna 10, can be placed on the signal path and thereby constrained in size according to the intended wavelength.

[0098] The antenna frame 212 of the antenna 210 is unitary. That is, the antenna frame is additively manufactured as a single component, thereby reducing the overall assembly required for the antenna 210. The single component antenna frame 212 can also improve the reliability of the antenna 210 and / or reduce the failure modes of the antenna.

[0099] The antenna frame is configured to be manufactured without the need for auxiliary support. In other words, after the antenna is manufactured, there is no need to remove a support structure. In particular, the overhanging features of the antenna, including the web 224, are designed to self-support at an angle of inclination. The described embodiments of the antenna frame 212 require limited post-processing in the form of machined detail features such as fastener holes. The antenna can be configured such that surface roughness resulting from the manufacturing is sufficiently limited that no entire surface finishing is required.

[0100] The antenna frame 212 can be configured to be manufactured by direct metal laser sintering (DMLS). The antenna includes a sintered aluminum alloy, in particular, in the present embodiment, of the AlSi10Mg Type II. The alloy can provide good strength, hardness, and high load tolerance, as well as low weight. Any metal or alloy with similar properties can be used in any viable additive manufacturing process.

[0101] C. Illustrative method of additive manufacturing

[0102] This section describes steps of an illustrative method for additive manufacturing of a workpiece; see Figure 10 Aspects of the illustrative additive manufacturing apparatus described in Figure 11 may be utilized in the method steps described below. If desired, reference can be made to the components and systems used in completing the various steps. These references are made for illustration and are not intended to limit the possible ways in which any particular step of the method can be completed.

[0103] Figure 10 is a flowchart illustrating steps performed in an illustrative method and does not necessarily depict the entire process or all steps of the method. Although the various steps of the method 300 are described below and depicted in Figure 10 , not all of the steps need necessarily be performed, and in some cases, steps can be performed simultaneously or in a different order than the illustrated order.

[0104] At step 310, digital information describing a plurality of layers in an order is received. As described in Figure 11 , the digital information can be received by a computer controller 412 of the additive manufacturing apparatus 410. The additive manufacturing apparatus can also be referred to as a printer or a fabricator. The computer controller 412 can include any data processing system configured to receive digital design information and control the functions of the printer 410. Figure 11 The illustrative computer controller shown in includes a processor 414 for controlling the functions of the printer and a memory 416 for storing received data.

[0105] The received information can include geometry data and / or design details regarding a plurality of two-dimensional patterns that make up layers of a three-dimensional object, where the three-dimensional object is the workpiece 428 to be manufactured. For example, as described above, the workpiece 428 can be a cup dipole antenna. The layers can also be described as cross-sections or slices. The plurality of layers are ordered such that the layers can be numbered or organized from a first layer to a last layer.

[0106] Step 312 of the method 300 includes depositing a raw material on a build platform 418 located in the established environment 420 of the printer 410. The build platform can include a support that is moved by the computer controller 412 along a manufacturing axis 422. The build platform can have a flat surface that is perpendicular to the manufacturing axis 422.

[0107] The raw material can be any material suitable for additive manufacturing, typically a fluid or powder, and includes, but is not limited to, photopolymer resin, thermoplastic, plaster, ceramic, and metal. For the previously described antenna, the raw material can be aluminum alloy powder. The material can be dispensed from a raw material source 424 such as a hopper, tank, or powder bed. For example, the aluminum alloy powder can be swept from a powder bed above the build platform 418 by a brush arm actuated by the computer controller 412.

[0108] The raw material can be distributed uniformly over the build platform 418 or can be deposited in a selected pattern. The deposition can be accomplished under the control of the computer controller 412. In some embodiments, the build platform 418 can be submerged in the raw material and the deposition can be accomplished by gravity or fluid pressure. In some embodiments, a print head 426 connected to the raw material source 424 can deposit the raw material in a pattern corresponding to the first layer of the ordered plurality of layers.

[0109] At step 314, the raw material is altered to produce the first layer. In other words, a physical change is introduced in the deposited material to realize the first layer as a physical object on the build platform according to the design information describing the first layer of the ordered plurality of layers and as directed by the computer controller 412.

[0110] The print head 426 of the printer 410 controlled by the computer controller 412 can act on the material. For example, the print head can include a laser that cures a photopolymer by exposure to light. For the antenna described above, the print head 426 can include a laser that sinters a metal alloy powder by exposure to heat. The print head can be directed by the computer controller 412 to follow a path defined in the received digital information of the first layer and / or a path calculated by the processor 414 based on the received digital information.

[0111] Step 316 includes repositioning the build platform. In some embodiments, the build platform 418 can be repositioned a selected distance from the print head 426. The selected distance can be determined by a program executed by the print head. After a layer is produced, the build platform is repositioned by the computer controller 412 along the build axis 422 away from the print head 426 by a thickness of the layer. That is, the build platform can be moved so that the top surface of the produced layer is a selected distance from the print head 426.

[0112] In some embodiments, the build platform 418 can be aligned with another element of the printer 410, such as a raw material dispensing component. After a layer is produced, the build platform can be repositioned by the computer controller 412 along the build axis 422 so that the top surface of the produced layer is aligned with the other element of the printer 410. In some embodiments, the print head 426 can be repositioned instead of or in addition to the build platform 418 at step 316. In some embodiments, step 316 can be skipped.

[0113] At step 318, raw material is deposited on the layer produced in the previous step of the method 300. As described for step 312, the raw material can be any suitable material and can be deposited in any suitable manner. At step 320, the raw material is altered to produce the next layer as previously described for step 314.

[0114] Steps 316 through 320 can be repeated to produce each of a plurality of layers of the received digital information until the last layer is produced. Thus, the produced first through last layers can comprise the workpiece 428 as described in the received digital information. The workpiece can be removed from the printer and post-processed as desired. For example, the antenna described above can be machined or can be a wire cut from the build plate of the build platform, and then the fine details or smooth surface of the antenna can be further finished by machining or other methods.

[0115] D. Illustrative method

[0116] This section describes steps of an illustrative method for manufacturing an antenna; see Figure 12 Aspects of the previously described antenna components, additive manufacturing methods, or additive manufacturing equipment can be utilized in the method steps described below. If desired, reference can be made to the components and systems used in completing the various steps. These references are made for illustration and are not intended to limit the possible ways in which any particular step of the method can be completed.

[0117] Figure 12is a flowchart showing steps performed in an illustrative method and does not necessarily illustrate the complete process or all steps of the method. Although the following describes and illustrates the method below and in FIGS. 3-5, the method can be performed in a different order than shown and described, and in some cases, simultaneously. Figure 12 The various steps of the method 500 are described below in FIG. 5, however, it is not necessary that all steps be performed and in some cases, steps can be performed simultaneously or in a different order than shown.

[0118] At step 510, the method includes printing a cup structure. The printing can include additive manufacturing according to any suitable method, including but not limited to the illustrative method 300 described above. Sub-step 512 of step 510 includes printing a floor portion (may also be described as a base or reflector) of the cup structure. The floor portion can be circular and / or can be configured for mounting a complete antenna. The build axis or orientation of the printing process can be perpendicular to the planar extent of the floor portion. In some embodiments, the floor portion can be printed directly onto the build plate or support platform of the additive manufacturing device.

[0119] Sub-step 514 of step 510 includes printing a peripheral wall of the cup structure. The wall can extend upward from the floor portion and can enclose an area of the floor portion. The wall can be disposed along the perimeter of the floor portion, and / or the floor portion can extend beyond the wall. The wall can be circular or cylindrical, about an axis perpendicular to the floor portion. The build axis or orientation of the printing process can be parallel to the central axis of the wall, and the wall can be printed as an integral structure with the floor portion.

[0120] Optional sub-step 516 of step 510 includes printing a mesh. The mesh can include a portion or all of the peripheral wall of the cup structure. In some embodiments, the mesh can also include a portion or all of the floor portion. The mesh can be described as a plurality of openings or holes and / or a wall structure having a plurality of openings or holes. The openings of the mesh can be arranged in a regular repeating pattern. The openings can have a diamond and / or triangular shape and can be positioned such that any side of the opening does not form an included angle with the build axis of the printing process of greater than about 45 degrees or 50 degrees.

[0121] The size of the openings of the mesh can be selected according to the intended range of radio frequencies. That is, the openings can be smaller than a selected portion of the minimum wavelength of the intended radio frequency transmission or reception. The openings can be small enough to avoid a significant impact on the transmission or reception of the antenna.

[0122] Step 518 of the method 500 includes printing a dipole structure. The dipole structure can extend from an area of the floor portion proximate the central axis of the peripheral wall and / or from a central area of the floor portion. The dipole structure can be configured for use as a dipole antenna, such as a bowtie antenna, crossed dipole, or halo antenna. The dipole structure can include one or more dipoles of any effective shape or configuration, and can include a feed structure, such as a balun.

[0123] Optional sub-step 520 of step 518 includes printing a mesh. The mesh can include a portion or all of the dipole structure. For example, the mesh can include a portion of each pole of the dipole structure. The mesh can be described as a planar structure having a plurality of openings or holes and / or a plurality of openings or holes. The openings of the mesh can be arranged in a regular repeating pattern. In some embodiments, the mesh can include a single opening in each pole of the dipole structure.

[0124] The openings can have a diamond and / or triangular shape and can be positioned such that no arbitrary side of the opening forms an included angle greater than about 45 degrees or 50 degrees with a build axis of the printing process. The size of the openings of the mesh can be dependent on the intended range of radio frequencies. That is, the openings can be smaller than a selected portion of the minimum wavelength of the intended radio frequency transmission or reception. The openings can be sufficiently small enough to avoid a significant impact on the transmission or reception of the antenna.

[0125] Method 500 can include either optional sub-step 516 or optional sub-step 520, or both, but can include printing at least one mesh. In some embodiments, the method can further include post-processing of the cup and / or dipole structure.

[0126] Illustrative combinations and additional embodiments

[0127] This section describes additional aspects and features of the antenna apparatus and components presented, but not limited to, a series of paragraphs in which a portion or all of it is presented in alphanumeric form for clarity and efficiency. Each of these paragraphs can be combined with one or more other paragraphs, and / or the disclosure portions elsewhere in this application, by any suitable means. Some of the following paragraphs explicitly refer to and further limit other paragraphs, providing but not limited to some embodiments of suitable combinations.

[0128] A0. An antenna apparatus comprising: a cavity structure having a floor portion and a wall portion connected to the floor portion; a dipole structure extending upward from a central region of the floor portion within the cavity structure, wherein the wall portion has an opening relative to an intended radio frequency wavelength sufficiently small to avoid impacting antenna performance with at least one of the dipole structure.

[0129] A1. The antenna apparatus of A0, wherein the cavity structure and the dipole structure are made by additive manufacturing.

[0130] A2. The antenna apparatus of A0 or A1, wherein the wall portion is circular.

[0131] A3. The antenna apparatus of any of A0 to A2, wherein the opening is diamond shaped.

[0132] A4. The antenna apparatus of any of A0 to A3, wherein the wall portion or the dipole structure comprises a mesh.

[0133] A5. The antenna apparatus of A4, wherein the mesh has diamond shaped openings.

[0134] A6. The antenna apparatus of any of A0 to A5, wherein substantially the entire wall portion is comprised of a printed mesh.

[0135] A7. The antenna apparatus of any of A0 to A6, wherein the dipole structure has triangular shaped openings.

[0136] A8. The antenna apparatus of any of A0 to A7, wherein the openings have a maximum dimension less than 105 of an intended wavelength.

[0137] A9. The antenna apparatus of any of A0 to A8, wherein the cavity structure comprises a laser sintered metal alloy.

[0138] A10. The antenna apparatus of any of A0 to A9, wherein the antenna apparatus is configured to operate within the L band of radio frequencies and the openings have a maximum dimension of about half an inch (1.27 centimeters (cm)).

[0139] A11. The antenna apparatus of any of A0 to A9, wherein the antenna apparatus is configured to operate within the L band of radio frequencies and the openings have a maximum dimension of about a quarter of an inch (6.35 millimeters (mm)) or less.

[0140] A12. The antenna apparatus of any of A0 to A9, wherein the antenna apparatus is configured to operate within the S band of radio frequencies and the openings have a maximum dimension of about a quarter of an inch (6.35 mm).

[0141] A13. The antenna apparatus of any of A0 to A9, wherein the antenna apparatus is configured to operate within the S band of radio frequencies and the openings have a maximum dimension of about an eighth of an inch (3.175 mm) or less.

[0142] A14. The antenna apparatus of any of A4 to A13, wherein the mesh has a thickness between 20 mils (0.508 mm) and 120 mils (3.048 mm).

[0143] B0. An antenna apparatus comprising: an additively manufactured cup-shaped structure having a floor portion and a peripheral wall portion connected to the floor portion; an additively manufactured dipole structure extending upward from the floor portion; wherein at least one of the wall portion and the dipole structure comprises an additively manufactured mesh.

[0144] B1. The antenna device of B0, wherein the mesh includes openings, each opening having a maximum dimension less than 10% of the expected wavelength.

[0145] B2. The antenna device of B0 or B1, wherein the cup-shaped structure includes a laser sintered metal alloy.

[0146] B3. The antenna device of any of B0-B2, wherein the mesh includes an array of diamond-shaped openings.

[0147] B4. The antenna device of any of B0-B3, wherein the mesh has a thickness between 20 mils (0.508 mm) and 120 mils (3.048 mm).

[0148] B5. The antenna device of any of B0-B4, wherein the mesh has diamond-shaped openings.

[0149] B6. The antenna device of any of B0-B5, wherein the mesh includes openings, each opening having a maximum dimension small enough relative to the expected radio frequency wavelength to avoid impacting antenna performance.

[0150] B7. The antenna device of B6, wherein the maximum dimension is between about one-eighth of an inch (3.175 mm) and one-half an inch (1.27 cm).

[0151] B8. The antenna device of any of B0-B7, wherein the antenna is configured for operation within the L band of radio frequencies.

[0152] B9. The antenna device of any of B0-B8, wherein the antenna is configured for operation within the S band of radio frequencies.

[0153] C0. A method of manufacturing a cavity antenna, comprising: printing a cavity structure having a floor portion and a perimeter wall portion; and printing a dipole structure within the cavity structure; wherein at least one of the cavity structure and the dipole structure includes a mesh.

[0154] C1. The method of C0, wherein the mesh has openings small enough to avoid a significant impact on radio frequency transmission or reception.

[0155] C2. The method of C0 or C1, wherein substantially the entire perimeter wall portion is made of the mesh.

[0156] C3. The method of any of C0-C2, wherein the mesh has diamond-shaped openings.

[0157] C4. The method of any of C0-C3, wherein the perimeter wall portion and the dipole structure each include a mesh.

[0158] C5. The method of CO, wherein printing includes printing the mesh with openings small enough to avoid a significant impact on radio frequency transmission or reception.

[0159] C6. The method of CO or C5, wherein printing the cavity structure includes printing substantially the entire perimeter wall portion to include the mesh.

[0160] C7. The method of any of CO, C5, or C6, wherein printing the perimeter wall portion includes printing the mesh to have openings in a diamond shape.

[0161] C8. The method of any of CO or C5-C7, wherein printing includes printing each of the perimeter wall portion and the dipole structure to include the mesh.

[0162] C9. The method of any of CO-C8, wherein printing the cavity structure includes printing a floor portion of the cavity structure; and printing a perimeter wall of the cavity structure to extend upwardly from the floor portion and enclose an area of the floor portion.

[0163] C10. The method of any of CO-C9, wherein printing the cavity structure includes printing the mesh to include at least a portion of the perimeter wall and / or a portion of the floor portion.

[0164] C11. The method of C10, wherein printing the mesh includes printing the mesh to include openings having a diamond or triangular shape, and the mesh is positioned such that any side of the openings does not make an included angle with the printed established axis of greater than about 45 degrees or 50 degrees.

[0165] C12. The method of any of CO-C11, wherein printing the dipole structure includes printing the mesh to include a portion or all of each pole of the dipole structure.

[0166] C13. The method of any of CO-C12, wherein printing the dipole structure includes printing the mesh to cause each pole of the dipole structure to include a single opening.

[0167] D0. An antenna component comprising: a hollow body portion comprising a laser sintered metal alloy, configured to guide radio frequency signals, the body portion comprising: a mesh configured to avoid a need for secondary printing to support and comprising openings small enough to avoid an impact on radio frequency transmission or reception.

[0168] D1. The antenna component of DO, wherein the body portion constitutes a portion of a command horn antenna.

[0169] D2. The antenna component of D0, wherein the body portion forms part of a cavity antenna.

[0170] D3. The antenna component of D2, wherein the body portion forms part of a cup dipole antenna.

[0171] Advantages, features, and benefits

[0172] The different embodiments of the additive manufactured antenna component described herein provide several advantages over known solutions for antenna design. For example, the illustrative embodiments described herein allow for manufacturing of antennas with reduced manual assembly.

[0173] In addition, and among other benefits, the illustrative embodiments described herein reduce weight, material requirements, and printing time.

[0174] In addition, and among other benefits, the illustrative embodiments described herein allow for additive manufacturing of precise circular holes.

[0175] In addition, and among other benefits, the illustrative embodiments described herein allow for additive manufacturing of antennas with precise geometry repeatedly.

[0176] In addition, and among other benefits, the illustrative embodiments described herein can reduce sensitivity to acoustic effects.

[0177] In addition, and among other benefits, the illustrative embodiments described herein can improve operational reliability.

[0178] Specifically, no known system or device can support these functionalities without the need for auxiliary support during the additive manufacturing process. However, not all embodiments described herein provide the same advantages or the same degree of advantages.

[0179] Conclusion

[0180] The present disclosure can encompass multiple distinct embodiments, each of which can include independent utilities. Although each of the embodiments has been described in its preferred form herein, various modifications are possible that fall within the scope of the present disclosure. Where a section heading is used herein, the heading is included for organizational purposes only. The subject matter of the present disclosure includes all novel and nonobvious combinations and subcombinations of the various elements, features, functions, and / or properties disclosed herein. The following claims particularly point out certain combinations and subcombinations that are regarded as novel and nonobvious. Other combinations and subcombinations can be claimed in the application or its subsequent modifications and equivalents. Such claims, whether broader, narrower, equal, or different, are regarded as within the subject matter of the present disclosure.

Claims

1. An antenna device (10, 110, 210), comprising: a cavity structure (12, 113, 213) having a floor portion (20, 118, 218) and a peripheral wall portion (13, 116, 216) connected to the floor portion (20, 118, 218); and a dipole structure (16, 117, 217) extending upwardly from a central region (137) of the floor portion (20, 118, 218) within the cavity structure (12, 113, 213), wherein the cavity structure (12, 113, 213) and the dipole structure (16, 117, 217) are made by additive manufacturing along a build axis perpendicular to the floor portion of the cavity structure, wherein the peripheral wall portion (13, 116, 216) and the dipole structure (16, 117, 217) comprise a mesh having diamond-shaped openings (15, 28, 127, 166, 227, 242) sufficiently small relative to an intended radio frequency wavelength (24) to avoid impacting antenna performance, each side of each diamond-shaped opening forming an angle with the build axis of less than 50 degrees, and wherein the mesh of the peripheral wall portion is additive manufactured without the use of auxiliary support.

2. The antenna device (10, 110, 210) according to claim 1, wherein, The peripheral wall portion (13, 116, 216) is circular.

3. The antenna device (10, 110, 210) according to claim 1, wherein, The dipole structure (16, 117, 217) has triangular-shaped openings (242).

4. The antenna device (10, 110, 210) according to any one of claims 1 to 3, wherein, The cavity structure (12, 113, 213) comprises a laser sintered metal alloy.

5. The antenna device (10, 110, 210) according to claim 1, wherein, The entire peripheral wall portion (13, 116, 216) is composed of a printed mesh (14, 26, 124, 164, 224).

6. A method (500) of manufacturing a cavity antenna (10, 110, 210), the method comprising: printing a cavity structure (12, 113, 213) having a floor portion (20, 118, 218) and a peripheral wall portion (13, 116, 216) along a build axis perpendicular to the floor portion (510); and printing a dipole structure (16, 117, 217) within the cavity structure (12, 113, 213) (518), wherein the cavity structure (12, 113, 213) comprises a mesh (14, 26, 124, 164, 224) having diamond-shaped openings, each side of each diamond-shaped opening forming an angle with the build axis of less than 50 degrees.

7. The method (500) of claim 6, wherein, Printing the cavity structure (12, 113, 213) (510) comprises: printing the floor portion (20, 118, 218) of the cavity structure (12, 113, 213) (512); and printing the perimeter wall portion (13, 116, 216) of the cavity structure (12, 113, 213) (514) to extend upwardly from the floor portion (20, 118, 218) and to enclose an area of the floor portion (20, 118, 218).

8. The method (500) of claim 6, wherein, printing the cavity structure (12, 113, 213) (510) comprises printing the web (14, 26, 124, 164, 224) (516) to include at least part of the perimeter wall portion (13, 116, 216) and / or part of the floor portion (20, 118, 218).

9. The method (500) according to any one of claims 6 to 8, wherein, printing the dipole structure (16, 117, 217) (518) comprises printing a web (14, 26, 124, 164, 224) (520) to include part or all of the dipole structure (16, 117, 217).

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