We demonstrate a new method for realizing Luneburg lens antennas with nearly continuously graded permittivity profiles in three dimensions. The method combines fused filament fabrication, a nearly ubiquitous additive manufacturing technique, with an effective media approach that employs space-filling curves. We experimentally validate our design methodology by fabricating and characterizing two Luneburg lenses designed to operate at separate frequency bands (26–40 GHz and 70–110 GHz) with antenna gains of 20 and 24 dBi, respectively. The results demonstrate good agreement with rigorous electromagnetic simulations. We also demonstrate the ability to passively beam steer over a wideband of operation (26–40 GHz and 70–110 GHz) with less than 0.5% power loss due to dielectric material losses within the Luneburg lens.

A conformal metasurface antenna exhibiting a pencil beam radiation pattern at 10.0 GHz has been designed using the Voronoi partition approach, and fabricated on the Kahu Uninhabited Aerial System (UAS) fuselage. Two manufacturing methods are presented and compared. The first approach utilized a 3-axis Trotec fiber laser to etch the flattened metasurface geometry in copper foil. The etched pattern was then ‘stretched’ over the UAS geometry. The second approach utilized a 6-axis nScrypt (retrofitted with an IDS aerosol jetting tool) to conformally print the metasurface pattern directly on the UAS fuselage. An electroless copper plating step was then utilized to improve the radiofrequency (RF) conductivity of the printed silver. Both manufacturing methods yielded functional metasurface antennas with equivalent performance at the operating frequency. However, the first method is limited to geometries that can be ‘flattened’ with acceptable tolerances, whereas the second approach is amenable to all practical geometries. This demonstration of two manufacturing techniques is a critical step forward in the cost-effective deployment of truly conformal metasurface antennas on realistic geometries.

Passive imaging using millimeter waves (mmWs) has many advantages and applications in the defense and security markets. All terrestrial bodies emit mmW radiation and these wavelengths are able to penetrate smoke, blowing dust or sand, fog/clouds/marine layers, and even clothing. One primary obstacle to imaging in this spectrum is that longer wavelengths require larger apertures to achieve the resolutions typically desired in surveillance applications. As a result, lens-based focal plane systems tend to require large aperture optics, which severely limit the minimum achievable volume and weight of such systems. To overcome this limitation, a distributed aperture detection scheme is used in which the effective aperture size can be increased without the associated volumetric increase in imager size. However, such systems typically require high frequency (~ 30 - 300 GHz) signal routing and down conversion as well as large correlator banks. Herein, we describe an alternate approach to distributed aperture mmW imaging using optical upconversion of the mmW signal onto an optical carrier. This conversion serves, in essence, to scale the mmW sparse aperture array signals onto a complementary optical array. The optical side bands are subsequently stripped from the optical carrier and optically recombined to provide a real-time snapshot of the mmW signal. In this paper, the design tradeoffs of resolution, bandwidth, number of elements, and field of view inherent in this type of system will be discussed. We also will present the performance of a 30 element distributed aperture proof of concept imaging system operating at 35 GHz.

We present the design and characterization of fully additively manufactured (AM) SubMiniature version A (SMA) connectors for use up to 18 GHz. Three-dimensional printed connectors can be directly integrated into the radio-frequency (RF) circuit without post-process bonding and can be fabricated into unusual shapes. The flexibility this affords in the manufacturing process offers significant advantages, especially for applications that need to meet strict size and volume constraints. To that end, we describe modifications to the traditional SMA design that better enable AM fabrication. A variety of different connector geometries were printed and fully characterized both electromagnetically and mechanically. Experimental measurements up to 18 GHz demonstrated good RF performance with low insertion losses (< 0.5 dB). Mechanical testing showed that the printed connectors could withstand up to 4.5 kg of direct force for extended periods of time without damage to the printed threads or other connector parts. Additionally, the printed connectors demonstrated good RF performance after repeated use.

We describe a computational imaging technique to extend the depth-of-field of a 94-GHz imaging system. The technique uses a cubic phase element in the pupil plane of the system to render system operation relatively insensitive to object distance. However, the cubic phase element also introduces aberrations but, since these are fixed and known, we remove them using post-detection signal processing. We present experimental results that validate system performance and indicate a greater than four-fold increase in depth-of-field from 17rdquo to greater than 68rdquo.

A fiber optic sensor developed for the measurement of tendon forces was designed, numerically modeled, fabricated, and experimentally evaluated. The sensor incorporated fiber Bragg gratings and micro-fabricated stainless steel housings. A fiber Bragg grating is an optical device that is spectrally sensitive to axial strain. Stainless steel housings were designed to convert radial forces applied to the housing into axial forces that could be sensed by the fiber Bragg grating. The metal housings were fabricated by several methods including laser micromachining, swaging, and hydroforming. Designs are presented that allow for simultaneous temperature and force measurements as well as for simultaneous resolution of multi-axis forces. The sensor was experimentally evaluated by hydrostatic loading and in vitro testing. A commercial hydraulic burst tester was used to provide uniform pressures on the sensor in order to establish the linearity, repeatability, and accuracy characteristics of the sensor. The in vitro experiments were performed in excised tendon and in a dynamic gait simulator to simulate biological conditions. In both experimental conditions, the sensor was found to be a sensitive and reliable method for acquiring minimally invasive measurements of soft tissue forces. Our results suggest that this sensor will prove useful in a variety of biomechanical measurements.