automated 3d printed electronicsutminers.utep.edu/pdeffenbaugh/20140514_imaps_3d.pdf · home, no...
TRANSCRIPT
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Automated 3D Printed Electronics
Paul Deffenbaugh
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Partners
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Application
1. Printed smartphones
2. Home products
3. Military mobile communications
4. Printed satellites,space hardware
1. Low time-to-market, on-demand manufacturing
2. Consumers may print at home, no trips to the store or delivery trucks
3. Battlefield, remote, carrier manufacturableelectronics
4. Ship bulk raw materials compactly to orbit, then print what is needed
Benefit
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Why Printed?
• Cost
• Environmental
• Personalization
• No manufacturing line
• Localization, jobs,distribution
Direct-Write Printing Process
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What’s Available?
Conductive
Paste / Silver Ink• Electrical
Strong
FDM / ABS
• Structural/case
Dielectric
High-K Ceramic
• RF/microwave/
• wireless
Sticky
Epoxy or Silicone
• Bond small parts
• Waterproof
Heat Laser
• Cures inks, epoxies, silicones
High intensity UV
• Cures resins
Pick and Place
• Chips, LCR, LEDs
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FDM: Fused Deposition Modelling
nScrypt nFD
Feed motor
Plastic filament, 1.75 mm
Feed system
Thermal isolation
Heater, max 400 °C
Nozzle, <0.2 mm
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PLA
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ABS
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Polycarbonate
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ULTEM
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SL
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SmartPump™Direct Print Additive Manufacturing
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Conductors
• Silver Micro-Flake Ink, ~5 μm flakes
• Dupont CB-028• Polymer base, heat-cures
• Cu: 0.7 ohm/sq• Ag Ink: 7-10 ohm/sq
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Laser Sinter Traces
• Sinter flakes to form solid silver
• Picosecond laser
• In-process
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Resistives
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Printable Epoxy or Silicone
Conductive 2-part epoxy
Standard 2-part high strength epoxy
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Loaded Silicone
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UV Ceramic
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Printed and Sintered
Green State Pyramid Post-fired Pyramid(Hollow Center)
Green State Post-fired
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Laser Sintered Ceramic
Klocke, Ader, Fraunhofer Inst. Production Tech., Germany
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Laser Sintering / EBM: Electron Beam Melting
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Integrated Pick and Place
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Multinozzle
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DIFFICULTIES
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FDM Roughness
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FDM Roughness Options
• Attempted
– Machining (facing)
– Pore filling (liquid SL application)
– Baking
• Ideal
– Parameter adjustment
– Pore coating (UV-ceramic)
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FDM Roughness
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UV Overcoat
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Ceramic-Coated FDM
• FDM core for strength
• SLA for smooth surface
• Ceramic-loading for low loss
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Solved!
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APPLICATION NOTES
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Elements
400 pF 35 nH
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Model plane wing
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Flashing blinky light
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Design, print
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Pick and Place
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Conductive
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Laser cure
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Flashing blinky light
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MICROWAVES AND 3D PRINTING
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Conventional RF
• Core i7 QuickPath– 20 differential pair
– 3.2 GHz = 204 Gbps
• DirecTV– 5 separate bands, 1 unit
– 2 to 40 GHz
– Ka/Ku band (18.5~40 GHz)
• iPhone 4s– 64 bit bus/32 Gbps
– CDMA/GSM/BT/Wifi/GPS
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Conventional RF
• Copper on FR-4
• Gold-plated copperon ceramic
• Example: DirecTV Dish– Ka/Ku band (18.5~40 GHz)
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Capacitor-Based
1 - 2 MHz100 MHz-1GHz
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Waveguide
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Cavity
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Ring Resonator
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Dielectric Loss
• DSM Somos Prototherm– εr = 3.6
– tan δ = 0.04 @ 2.4 GHz
– tan δ = 0.1 @ 10 GHz
• Rogers LCP– εr = 2.9
– tan δ = 0.0025 @ 10 GHz
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Conductor Loss
• Lossy:– ρ = 216 nΩm (8.5 Ω/□/mil)
• Flake-flake layers
• Rough μ-flake surface
• Low Loss– ρ = 17 nΩm (0.7 Ω/□/mil)
• Solid metal
• Smooth metallic surface
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Silver ink on SL
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Microstrip
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Microstrip
Silver Flake Ink Copper Tape
ProtothermSLA
Rogers LCP
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Microstrip
• VNA S-Parameter Analysis
• Loss mechanisms
• Material properties
Microstrip Multi-moding
Lossy Media
Microstrip
h = 30 mil
w ≈ 75 mil
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CREATIVITY
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ArtificialSpatially-variant
AnisotropicMeta-materials
Field Control
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Metamaterials
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Creativity
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Air Filled Microstrip
• Realized 10 mil features
• May reduce loss by 4X
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Curved Substrates
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ANTENNAS
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3D Printed AntennaABS Filament
Silver Flake Thick Film Paste
nScryptFDM
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Design
• Planar inverted “F” antenna
• Requires thick dielectric or floating metal
• Quarter-Wave / Dipole
• End-fire nulls
• Patch
• Highly directional
• Inverted “F” Antenna
• Simple, one-sided
Quarter-Wave
IFA
PIFA
Patch
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Fully 3D Printed 2.4 GHz Bluetooth/Wi-Fi Antenna
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Fully 3D Printed 2.4 GHz Bluetooth/Wi-Fi Antenna
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EPO-TEK H20e
Silver 2-part conductive epoxyGood adhesion
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Dupont CB-028
Silver flake conductive inkGood conductivity
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SWR
Blue solid: measured
Green dashed: model
Red dotted: design
Measured:
2.2 SWR at 2.45 GHz
Design:
2:1 SWR from 2.32 – 2.58 GHz
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Return Loss
Blue solid: measured
Green dashed: model
Red dotted: design
Measured:
- 8dB at 2.45 GHz
Design:
-10 dB bandwidth is 14.4 %
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Radiation
• 5.6 dB max gain
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Measurement
Class 1 Bluetooth Spec. 100 m
Quarter-Wave Antenna 114 m
3D Printed Inverted F-Antenna 107 m
100 m
Transceiver 1 Quarter-Wave Printed IFA Transceiver 2
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Curved IFA
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Conclusion
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Bare Die
Packaged Die
Packaged Circuit Board Sub Assembly
Packaged Chassis Assembly Packaged Rack Assembly
Package of Packages
$
$
$
$$
$
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3D Printed Harness and Connectors For Satlets
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Conclusion