Shadowed Substrate Coating for Mask-Free Electromagnetic Devices
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Solution Overview
Problem
Current additive manufacturing techniques struggle to combine both conductive and dielectric materials in a single substrate for electromagnetic devices, leading to material limitations and issues with complex designs, as they require external masks that can be difficult to design and maintain, resulting in electrical shorts and inadequate control over conductive material deposition.
Innovation Solution
Incorporating shadowing features directly into the substrate during manufacturing, allowing for the controlled deposition of conductive materials without external masks, enabling the creation of electromagnetic devices with both polymer and metal components, such as frequency selective surface elements and printed circuit boards, where shadowing features protect specific areas from being coated, thereby controlling conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If external masks are used to control conductive material deposition, then coating precision is improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The patent merges the substrate and the masking function into a single integrated structure. Shadowing features are formed as integral parts of the substrate itself, eliminating the need for separate external masks. This combination resolves the contradiction by maintaining deposition control while removing the complexity of separate mask components and their assembly.
Solution Approach 2:
The patent extracts the masking function from external components and relocates it directly into the substrate structure. By forming shadowing features within the substrate, the control function is extracted from the external mask system and embedded into the substrate, simplifying the overall device architecture while preserving precision.
2Manufacturing precision
If external masks are used for complex designs, then coating precision is improved, but ease of manufacture deteriorates
Solution Approach 1:
The substrate and masking features are merged into a single manufacturable unit. The shadowing features are formed during substrate manufacturing using standard additive manufacturing techniques, eliminating the need for separate mask production, alignment, and assembly processes. This integration significantly improves ease of manufacture while maintaining precise conductive material placement.
3Adaptability or versatility
If additive manufacturing is used to combine conductive and dielectric materials, then material versatility is improved, but manufacturing precision deteriorates due to electrical shorts
Solution Approach 1:
The patent applies local quality by creating shadowing features with specific geometries at precise locations on the substrate. These features selectively block conductive material deposition in certain areas while allowing it in others, enabling precise control of electrical conductivity patterns. This local control prevents unwanted electrical shorts while maintaining the ability to combine multiple materials.
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 method allows for the production of complex electromagnetic devices with improved conductivity control, reducing the need for external masks and minimizing electrical shorts, while enabling the creation of devices with both conductive and dielectric properties in a single substrate, enhancing performance and reducing manufacturing costs.
Implementation Method 1
coating portions of the substrate with a conductive material... shadowing features fabricated thereon... shadowing features protect specific areas from being coated
Data Source
AI summary
Systems and methods for producing electromagnetic devices are provided. The systems and methods allow for an electromagnetic device having both a substrate (e.g., polymer) and conductive material (e.g., metal) to be manufactured without using masks or other outside objects disposed over a surface (e.g., the substrate) onto which the conductive material is deposited. In one exemplary embodiment, the method includes performing additive manufacturing using a polymer to produce a device having a plurality of interconnected walls and a plurality of frequency selective surface elements, and then coating portions of the device with a conductive material. A plurality of shadowing features are formed as part of one or more of the walls to protect the frequency selective surface elements from being coated by the conductive material. Other methods, and a variety of systems that can result from the disclosed methods, are also provided.