We propose the use of 3D-printed helix antennas for millimeter-wave radar imaging. This concept is promising for a number of reasons: Additive manufacturing involving 3D-printing is a relatively cost efficient fabrication technique and offers increased geometrical freedom of design compared to conventional manufacturing processes. From an imaging point of view, using helix antennas is advantageous because of the circular polarization the antennas emit. That way, imaging thin dipole-like structures is possible regardless of their orientation. In contrast, imaging systems using linearly polarized antennas are unable to image dipoles orientated orthogonally to their polarization direction. Radar systems using circular polarization additionally enable polarimetric imaging and decomposition. In security screening this can achieve a higher classification accuracy in discriminating threat objects and reduce false alarms. Furthermore, the thin helix antennas (typical coil diameter: ca. 1.5 mm) can be mounted very closely to each other, which is interesting for array design. A security screening example was investigated for demonstration: A cardboard box with metallic and dielectric threat objects was screened at 70 GHz – 90 GHz by a quasi-monostatic synthetic aperture radar consisting of two 3D-printed helix antennas, one right-hand and one left-hand circularly polarized. As a reference, the same object was screened with split-block linearly polarized horn antennas. With the proposed setup, the resolution of the reconstruction images was comparable to that of the reference system. However, the circular polarization was able to depict thin structures in a better fashion than the linearly polarized reference system.
Additive manufacturing has already found broad acceptance in rapid prototyping of machinery and is an emerging technology in many other fields such as radio frequency (RF) engineering, where the advantages of the so-called 3D printing technology overcome limitations of established processes and allow entirely new designs. The ability to create almost arbitrary shapes with high precision has proven very useful for antenna design, for example.
Using conductive and dielectric ink, RF transmission lines can be 3D printed directly on uneven surfaces. As for RF structures geometrical dimensions are crucial for the resulting RF properties such as impedance, a technique to measure the distance between the printing nozzle and the substrate is necessary. This turns out to be a challenging task since a small spot size is required and transparent (dielectric) as well as reflective (conductor) materials must be detected while maintaining a mechanically flexible and robust system.
We propose a distance measurement system based on coherent optical frequency domain reflectometry to accurately measure this distance. The proposed miniaturized coupling optic uses a gradient-index (GRIN) lens with a diameter of less than 3 mm, can be integrated into a printing head easily and is compatible to standard single-mode fibers. In first experiments, we have achieved very promising results that show a good agreement with (destructive) microscopic measurements. Reflective and transparent surfaces can be detected with μm-accuracy.
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