3D Printed Waveguide Antenna at X-Band Frequency Band Using MSLA Printing Technology
Huda Bin Abdul Majid ,
Fahmiruddin Esa ,
Herdawatie Abdul Kadir ,
Azka Rehman ,
Hilman Harun ,
Muzammil Jusoh ,
Najib Al-Fadhali ,
Dian Widi Astuti and
Noor Azwan Shairi
Rapid advancements in 3D printing technology have revolutionized antenna fabrication, allowing for the creation of intricate, lightweight, and high-performance structures with exceptional precision. This paper presents the design, fabrication, and experimental evaluation of a 3D-printed waveguide antenna operating in the X-band frequency range (8-11 GHz). The antenna was manufactured using Masked Stereolithography Apparatus (MSLA) technology with Magma X 12 K Dura ABS resin, which was selected for its excellent mechanical strength and dielectric properties. A 0.2 mm thick silver conductive coating was applied to enhance the electrical conductivity and minimize the surface resistance. The proposed antenna is based on a WR-90 rectangular waveguide configuration with an optimized aperture, which ensures minimal reflection loss and high radiation efficiency. Experimental results indicate an impedance bandwidth of 1.34 GHz, spanning from 8.56 GHz to 9.9 GHz, with an optimal resonant frequency at 9.45 GHz. The measured and simulated S11 parameters exhibited strong agreement, validating effective impedance matching and minimal energy dissipation. Furthermore, radiation pattern analysis revealed a directional gain of 6.85 dBi and an overall radiation efficiency of 98.35%. The measured 3 dB beamwidths were 60.5˚ in the E-plane and 105.8˚ in the H-plane, confirming the suitability of the antenna for applications in satellite communication, radar, and wireless sensing. The results demonstrate the viability of MSLA-based additive manufacturing for high-frequency waveguide antennas, offering a cost-effective, lightweight, and high-performance alternative to the traditional fabrication techniques. This study highlights the potential of 3D printing as an innovative approach for the development of next-generation microwave and millimeter-wave communication systems.