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Register a new userMaterial survey for millimeter-wave absorber using 3-D printed mold
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Radio absorptive materials (RAMs) are key elements for receivers in the millimeter-wave range. For astronomical applications, cryogenic receivers are widely used to achieve a high-sensitivity. These cryogenic receivers, in particular the receivers for the cosmic microwave background, require that the RAM has low surface reflectance ($lesssim 1%$) in a wide frequency range (20--300 GHz) to minimize the undesired stray light to detectors. We develop a RAM that satisfies this requirement based on a production technology using a 3D-printed mold (named as RAM-3pm). This method allows us to shape periodic surface structures to achieve a low reflectance. A wide range of choices for the absorptive materials is an advantage. We survey the best material for the RAM-3pm. We measure the index of refraction ($n$) and the extinction coefficient ($kappa$) at liquid nitrogen temperature as well as at room temperature of 17 materials. We also measure the reflectance at the room temperature for the selected materials. The mixture of an epoxy adhesive (STYCAST-2850FT) and a carbon fiber (K223HE) achieves the best performance. We estimate the optical performance at the liquid nitrogen temperature by a simulation based on the measured $n$ and $kappa$. The RAM-3pm made with this material satisfies the requirement except at the lower edge of the frequency range ($sim$20 GHz). We also estimate the reflectance of a larger pyramidal structure on the surface. We find a design to satisfy our requirement.
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We present the design, manufacturing technique, and characterization of a 3D-printed broadband graded index millimeter wave absorber. The absorber is additively manufactured using a fused filament fabrication (FFF) 3D printer out of a carbon-loaded high impact polystyrene (HIPS) filament and is designed using a space-filling curve to optimize manufacturability using said process. The absorbers reflectivity is measured from 63 GHz to 115 GHz and from 140 GHz to 215 GHz and is compared to electromagnetic simulations. The intended application is for terminating stray light in Cosmic Microwave Background (CMB) telescopes, and the absorber has been shown to survive cryogenic thermal cycling.
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