3D Printed Dielectric Lattice for Electromagnetic Control
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Solution Overview
Problem
Current methods for manufacturing dielectric parts with controlled electromagnetic constants lack precision, particularly in achieving gradients and anisotropies, which is crucial for applications like miniaturized antennas in the microwave range, and fail to incorporate fluids effectively for thermal control and vacuum compatibility.
Innovation Solution
A method involving three-dimensional printing of a solid dielectric network with specific mesh structures that allow precise control of relative electromagnetic constants and fluid incorporation, enabling uniform fluid circulation and optimized mechanical, thermal, and optical characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If chemical or sol-gel methods are used to interweave dielectric materials, then the manufacturing process is simple, but the precision of electromagnetic constant control is poor (at best 10% precision)
Solution Approach 1:
The patent changes the manufacturing method from chemical/sol-gel processes to 3D printing technology, enabling precise control of the interweaving structure geometry. This parameter change allows exact control of material distribution and mesh dimensions, achieving electromagnetic constant precision far exceeding the 10% limitation of chemical methods.
Solution Approach 2:
The patent replaces chemical methods (sol-gel, chemical vapor deposition) with a mechanical 3D printing system. This substitution enables direct physical construction of the interweaving structure with programmable precision, allowing exact control of electromagnetic constants through digital modeling and additive manufacturing processes.
2Manufacturing precision
If mechanical processes (engraving, drilling, molding) are used to control nesting structure, then structure control is possible, but the process becomes long, complex and costly
Solution Approach 1:
The patent merges multiple separate mechanical operations (engraving, drilling, molding, assembly) into a single 3D printing process. The interweaving structure is manufactured in one additive manufacturing step, eliminating the need for sequential mechanical operations and reducing overall process complexity despite maintaining high structural control.
Solution Approach 2:
The patent performs preliminary digital modeling and simulation of the interweaving structure before manufacturing. The 3D printing process then directly fabricates the pre-designed complex geometry without requiring intermediate mechanical operations, reducing on-site manufacturing complexity while maintaining precise structure control.
3Reliability
If fluid dielectric material is incorporated into the dielectric part, then thermal control and vacuum compatibility are improved, but the requirement for simultaneous geometry freedom and positioning precision increases
Solution Approach 1:
The patent creates a porous interweving structure with controlled void spaces that can accommodate fluid dielectric materials. The 3D printing process generates a scaffold-like architecture with predetermined pore sizes and distributions, enabling precise control of fluid incorporation while maintaining structural integrity and geometric flexibility.
Solution Approach 2:
The patent nests fluid dielectric material within the solid dielectric interweaving structure. The 3D printed scaffold contains and organizes the fluid in specific regions, achieving precise spatial control of the fluid while allowing the overall structure to maintain geometric freedom for thermal and vacuum management.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach allows for the precise control of electromagnetic constants and fluid circulation within dielectric parts, enhancing their mechanical, thermal, and optical properties, making them suitable for high-precision applications like space and aeronautical industries.
Implementation Method 1
each dielectric material has at least one relative electromagnetic constant εr, μr of different values... the dielectric part has at least one tensor [εr], [μr] determined by at least one relative electromagnetic constant εr, μr
Implementation Method 2
printed by printing three-dimensional... manufacture of the three-dimensional solid network by three-dimensional printing of each solid dielectric material
Data Source
Figure 1
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AI summary
The present invention relates to a method for manufacturing a dielectric part in which a plurality of dielectric materials are interlocked, at least one of which is in solid state, and having at least one relative electromagnetic constant εr, µr with various values, by selecting (15) an interlocking structure formed by a three-dimensional solid lattice made up of a repetition in three directions of space of meshes of at least one solid dielectric material. The dielectric part is manufactured (16) by three-dimensional printing of the three-dimensional solid lattice such that the part has at least one predetermined tensor [εr], [µr] of at least one relative electromagnetic constant εr, µr.