A two-layer higher order mode circularly polarised (CP) rectangular dielectric resonator antenna (RDRA) is proposed at a frequency range of 10 to 13 GHz using a single-feed. The configuration incorporates the DRA and a dielectric coat with respective dielectric constants of 10 and 3.5. Utilising the outer layer offers a number of advantages such as wider impedance and CP bandwidths of μ21%, and 9.5%, respectively, as well as a high gain of ~11dBic. Close agreement has been achieved between experimental and simulated results.

Ultra-high molecular weight polyethylene (UHMWPE) is a thermoplastic semicrystalline polymer that has outstanding mechanical properties, low friction coefficient, excellent wear resistance, and is highly resistant to corrosive chemicals. UHMWPE is found in many applications including artificial joints and filtration. However, UHMWPE parts cannot be produced easily by traditional techniques, such as injection moulding and extrusion because of its very high melt viscosity owing to the extremely long polymer chains. Few attempts were made to process UHMWPE by additive manufacturing, particularly laser sintering. This is due to the lack of understanding of the powder properties of UHMWPE. Therefore, the aim of the powder characterisation process in this study is to gain a better understanding of the material requirements and provide a detailed insight on whether UHMWPE is a suitable material for laser sintering. The characterisation process includes powder morphological and flow characteristics, thermal behaviour and stability, and crystallinity of UHMWPE. The study reveals that the sintering behaviour of polymers is controlled by the morphology of the particles in addition to the viscous flow of UHMWPE. There are still difficulties of processing UHMWPE due to highly agglomerated structure of smaller particles with the presence of fibrils in the UHMWPE particles.

Ultra High Molecular Weight Polyethylene (UHMWPE) is a semi-crystalline polymer that has remarkable properties of high mechanical properties, excellent wear resistance, low friction and chemical resistance, and it is found in many applications such sporting goods, medical artificial joints, bullet proof jackets and armours, ropes and fishing lines [1]. UHMWPE parts cannot be produced easily by many conventional processes because of its very high melt viscosity resulting from its very long chains [2]. Additive Manufacturing (AM) is moving from being an industrial rapid prototyping process to becoming a mainstream manufacturing process in a wide range of applications. Laser sintering of polymers is one of the AM techniques that is most promising process owing to its ability to produce parts with complex geometries, accurate dimensions, and good mechanical strength [3]. This paper reports attempts to laser-sinter UHMWPE and assesses the effects of laser energy density on the flexural properties of the sintered parts. The properties of the UHMWPE sintered parts were evaluated by performing flexural three point bending tests and were compared in terms of flexural strength, flexural modulus and ductility (deflection). Part dimensions and relative density were evaluated in order to optimise the laser sintering parameters. Thermal analysis of samples was made by differential scanning calorimetry (DSC) for the virgin powder. Results show that flexural strength, modulus and ductility are influenced by laser energy density and flexural strength and modulus of 1.37MPa and 32.12MPa respectively are still achievable at a lower laser energy density of 0.016J/mm2 (Laser power of 6W). Part dimensions and bulk density are also influenced by laser energy density

Activated Carbon (AC) is widely available at a relatively low cost, has a high porosity and is commonly used as a filter material for a range of applications. However, it is a brittle and friable material. Ultra-High Molecular Weight Polyethylene (UHMWPE) polymer is a tough engineering plastic that has been used as a binder. The traditional method used in manufacturing AC/UHMWPE filters involves compressing AC/UHMWPE composite powder during heating in a mould. This process compresses the particles together and the materials undergo sintering. This process results in a low pore interconnectivity, which has a considerable impact on the filter’s efficiency. Selective Laser Sintering is a laser powder bed fusion additive manufacturing technique for polymers. This has a number of advantages compared to the conventional technique and produces a porous structure with improved filtration efficiency. We propose that this is due to the greater pore interconnectivity. In this work, AC/UHMWPE powdered composites were prepared with different AC and UHMWPE ratios. The structure and properties of the AC/UHMWPE composite were investigated and characterised to assess their suitability for selective laser sintering. Particle size and morphology analysis were conducted, as well as density measurements, powder flow, thermal analysis, and crystallinity measurements. The results reveal that the addition of AC improves the UHMWPE flow. The thermal analysis results show that the intrinsic thermal properties of UHMWPE powder are not significantly affected by the introduction of activated carbon. However, thermal gravimetric analysis revealed that the onset of mass loss is considerably shifted (20 °C) to higher temperatures for the AC/UHMWPE composites, which is favourable for laser sintering. Additionally, the change in the composition ratio of untreated composite does not have a significant effect on the degree of crystallinity. Laser-sintered AC/UHMWPE parts were successfully manufactured using a commercial laser-sintering machine.

Ultra High Molecular Weight Polyethylene (UHMWPE) has excellent properties, such as high mechanical performance, low friction, high wear and chemical resistance but so far there has been limited use in additive manufacturing (AM). Laser sintering of polymers is one of the most promising AM technologies due to its ability to produce complex geometries with accurate dimensions and good mechanical properties. Consequently, this study investigates the influence of laser power on physical and mechanical properties of UHMWPE parts produced by laser sintering. In particular mechanical properties, such as Ultimate Tensile Strength (UTS), Young’s Modulus and elongation at break were evaluated alongside relative density, dilation and shrinkage. Finally, the fracture surface of the tensile test specimens was examined by electron microscopy. Results show that within a laser power range of 6–12 W there appears to be an optimum where tensile strength and relative density reach a maximum, dilation is minimised and where elongation increases with laser power. UTS up to 2.42 MPa, modulus up to 72.6 MPa and elongation at break up to 51.4% were observed. Relative density and part dimensions are also influenced by laser power.

This article delves into the capabilities of 3D-printed millimeter-wave (mmWave) layered cylindrical dielectric resonator antennas (CDRAs). The proposed design yielded promising results, boasting a remarkable 53% impedance bandwidth spanning the frequency spectrum from 18 to 34 GHz. Furthermore, the axial ratio (AR) bandwidth achieved an impressive 17%, coupled with a maximum gain of 13.3 dBic. These notable results underscore the efficacy of the proposed design, positioning it as a viable solution for applications in Beyond 5G (B5G). A novel assembly technique was also investigated, employing additive manufacturing to seamlessly merge two layers with distinct dielectric constants into a singular layer. This innovative approach systematically eliminates the potential for air gaps between layers, enhancing the antenna’s overall performance. This approach exhibited potential, particularly in the performance of a millimeter-wave circularly polarized (CP) cylindrical DRA featuring a perforated coating layer. The synergy between measurements and simulations demonstrates a remarkable alignment, providing robust validation of the effectiveness of the proposed design.