Production method of millimeter-wave absorber with 3D-printed mold

Abstract

We established a production method of a millimeter-wave absorber by using a 3D-printed mold. The mold has a periodic pyramid shape, and an absorptive material is filled into the mold. This shape reduces the surface reflection. The 3D-printed mold is made from a transparent material in the millimeter-wave range. Therefore, unmolding is not necessary. A significant benefit of this production method is easy prototyping with various shapes and various absorptive materials. We produced a test model and used a two-component epoxy encapsulant as the absorptive material. The test model achieved a low reflectance: ∼1% at 100 GHz. The absorber is sometimes maintained at a low temperature condition for cases in which superconducting detectors are used. Therefore, cryogenic performance is required in terms of a mechanical strength for the thermal cycles, an adhesive strength, and a sufficient thermal conductivity. We confirmed the test-model strength by immersing the model into a liquid-nitrogen bath.