Arrays with three-dimensional conformal radiating elements

A method of fabricating an antenna array, the antenna array comprising a ground plane and a plurality of unit cells disposed on the ground plane, each unit cell comprising a three-dimensional (3D) conformal radiating element comprising a conductive material,

• the 3D conformal radiating element of each unit cell being conformal on a hemispherical shape,
• the method comprising:
• using a 3D printer to print the ground plane and the 3D conformal radiating element of each unit cell with a polymer;
• and
• disposing the conductive material on the ground plane and the 3D conformal radiating element of each unit cell,
• the method further comprising forming a switch on the 3D conformal radiating element of each unit cell,
• the 3D conformal radiating element of each unit cell comprising a central conductive portion and a plurality of dipole arms each connected to the central conductive portion via the switch, such that if the switch connecting a dipole arm to the central conductive portion via a switch is on, that dipole arm is active, and if the switch connecting a dipole arm to the central conductive portion via a switch is off, that dipole arm is not active.

A method of fabricating an antenna array, the antenna array comprising a ground plane and a plurality of unit cells disposed on the ground plane, each unit cell comprising a three-dimensional (3D) conformal radiating element comprising a conductive metal, the 3D conformal radiating element of each unit cell being conformal on a hemispherical shape,

• the method comprising:
• using a 3D printer to print the ground plane and the 3D conformal radiating element of each unit cell with a polymer;
• metallizing the ground plane and the 3D conformal radiating element of each unit cell with the conductive metal;
• and
• forming a switch on the 3D conformal radiating element of each unit cell,
• the 3D conformal radiating element of each unit cell having a circular mushroom shape,
• the metallizing of the ground plane and the 3D conformal radiating element of each unit cell being performed such that a portion of the polymer is not metallized,
• the portion of the polymer being an electrically insulating substrate disposed on the ground plane and on which the 3D conformal radiating element of each unit cell is disposed,
• the antenna array being a reflectarray or a transmitarray,
• the polymer being a thermoplastic, an amorphous polymer, or both,
• each unit cell having a maximum height, measured in a direction perpendicular to the ground plane, of 5 millimeters,
• the antenna array having a beamwidth coverage of at least 60° with a gain beamwidth drop from the broadside of no more than 3 decibels (dB), and
• the antenna array having a reflection phase range of at least 300°,
• the 3D conformal radiating element of each unit cell comprising a central conductive portion and a plurality of dipole arms each connected to the central conductive portion, and
• the plurality of dipole arms each being connected to the central conductive portion via the switch, such that if the switch connecting a dipole arm to the central conductive portion via a switch is on, that dipole arm is active, and if the switch connecting a dipole arm to the central conductive portion via a switch is off, that dipole arm is not active.

A method of fabricating an antenna array, the antenna array comprising a ground plane and a plurality of unit cells disposed on the ground plane, each unit cell comprising a three-dimensional (3D) conformal radiating element comprising a conductive metal, the 3D conformal radiating element of each unit cell being conformal on a hemispherical shape,

• the method comprising:
• using a 3D printer to print the ground plane and the 3D conformal radiating element of each unit cell with a polymer;
• and
• metallizing the ground plane and the 3D conformal radiating element of each unit cell with the conductive metal,
• the 3D conformal radiating element of each unit cell having a circular mushroom shape,
• the metallizing of the ground plane and the 3D conformal radiating element of each unit cell being performed such that a portion of the polymer is not metallized,
• the portion of the polymer being an electrically insulating substrate disposed on the ground plane and on which the 3D conformal radiating element of each unit cell is disposed,
• the antenna array being a reflectarray or a transmitarray,
• the polymer being a thermoplastic, an amorphous polymer, or both,
• each unit cell having a maximum height, measured in a direction perpendicular to the ground plane, of 5 millimeters,
• the antenna array having a beamwidth coverage of at least 60° with a gain beamwidth drop from the broadside of no more than 3 decibels (dB),
• the antenna array having a reflection phase range of at least 300°, and
• the circular mushroom shape comprising a plurality of cutout portions spaced equidistantly from each other circumferentially around the circular mushroom shape.