Fully Aerosol Jet-Printed Passive Components for 140220-GHz Operation

This letter focuses on the unique capabilities that aerosol jet printing (AJP) provides for manufacturing electronics at near-THz frequencies. For the first time, we demonstrate fully aerosol jet-printed passive components above the W-band. Dielectric substrates and conductors are printed on metal carriers via AJP. These components include microstrip (MS) transmission lines (TLs) and radial stubs, and utilize vialess grounded coplanar waveguide (GCPW)-to-MS TL launches. Two separate sets of components and calibration structures are realized, for two different dielectric thicknesses. For the TLs, measured from 140 to 220 GHz, the average loss varies from 0.86 to 2.6 dB/mm. The radial stub return loss, measured from 200 to 220 GHz, is closely aligned with simulations.

Automated summary

This letter discusses the unique capabilities of aerosol jet printing (AJP) in manufacturing electronics at near-THz frequencies. For the first time, fully aerosol jet-printed passive components above the W-band are demonstrated. Dielectric substrates and conductors are printed on metal carriers via AJP. These components include microstrip (MS) transmission lines (TLs) and radial stubs, and utilize vialess grounded coplanar waveguide (GCPW)-to-MS TL launches. Two separate sets of components and calibration structures are realized, for two different dielectric thicknesses. For the TLs, the measured average loss varies from 0.86 to 2.6 dB/mm from 140 to 220 GHz. The measured radial stub return loss from 200 to 220 GHz closely aligns with simulations.