Abstract
This paper presents the design, prototyping, and testing of an S-Band
conformal array on a partial wing surface. The array elements are series
fed microstrip patch antennas fabricated entirely through additive
manufacturing (AM) technology using a combination of fused deposition
modeling and thermal spray. A robust material set of ULTEM 9085 and
copper alloy is used for a good balance of mechanical/environmental
robustness and RF performance, while also offering a viable path forward
for a future fielded design. The focus of this paper is on AM
multi-material fabrication, fundamental print settings and material
characterization, and antenna testing. AM characterization coupons are
utilized to improve the accuracy of the RF antenna model, which showed
excellent agreement with the prototype measurements.