Research on Fused Deposition Integrated Manufacturing Process and Electromagnetic Camouflaging Properties of Metasurface Heterostructure

doi:10.3901/JME.2022.03.276

Abstract

Abstract: The integrated manufacturing of curvilinear conformal dielectric substrates and ordered metal unit cells of metasurface heterostructure is a bottleneck problem that hinders the development of metasurface electromagnetic camouflaging technology to engineering application. With the advantages of high design freedom and suitable for rapid prototyping of complex structures by 3D printing technologies, a fused deposition integrated manufacturing process of liquid metal and polymer heterostructure is proposed. Based on the existing polymer fused deposition molding (FDM) process, the stable deposition of fused Sn-Bi liquid metal on the polylactic acid (PLA) substrate is realized by the interface reinforcing mechanism of hot pressing and microstructure embedment. Afterward, the controllable forming of metal lines is realized by optimizing the process parameters such as printing extrusion flow and layer height. And the complex structure forming ability of fused deposition integrated manufacturing process is significantly improved by motion command correction and dynamic flow compensation. Finally, a trapezoidal metasurface electromagnetic camouflage structure is fabricated by the proposed fused deposition integrated manufacturing process of liquid metal and polymer. The electromagnetic measurement results show that the maximum generalized radar cross section (RCS) reduction of the designed metasurface sample is about -14.1 dB at x-polarization in the normal incidence electromagnetic wave, i.e. the electromagnetic reflection characteristics of the metasurface sample and the camouflage target reach about 96.1% similarity, and the 3 dB reduction (i.e. RCS reduced to 50%) bandwidth is about 33.6%, showing excellent electromagnetic camouflaging properties. An effective method is provided by the fused deposition integrated manufacturing process of liquid metal and polymer for the manufacturing of curvilinear conformal metasurface heterogeneous functional structures, which provides manufacturing technology support for promoting the development of metasurface to engineering applications.

Key words: metasurface, electromagnetic camouflage, heterostructure, fused deposition modeling, integrated manufacturing

CLC Number:

TH164

LIANG Qingxuan, YIN Haoyu, LI Zhaohui, DUAN Yubing, WANG Xin, LI Dichen. Research on Fused Deposition Integrated Manufacturing Process and Electromagnetic Camouflaging Properties of Metasurface Heterostructure[J]. Journal of Mechanical Engineering, 2022, 58(3): 276-283.

References

[1] YU Nanfang,GENEVET P,KATS M A,et al. Light propagation with phase discontinuities:generalized laws of reflection and refraction[J]. Science,2011,334(6054):333-337.
[2] 侯海生,王光明,李海鹏,等. 超薄宽带平面聚焦超表面及其在高增益天线中的应用[J]. 物理学报,2016,65(2):027701. HOU Haisheng,WANG Guangming,LI Haipeng,et al. Ultra-thin broadband flat metasurface to focus electromagnetic waves and its application in high-gain antenna[J]. Acta Physica Sinica,2016,65(2):027701.
[3] KHORASANINEJAD M,ZHUIT A Y,ROQUES-CARMES C,et al. Polarization-insensitive metalenses at visible wavelengths[J]. Nano Letters,2016,16(11):7229-7234.
[4] WANG Shuming,WU P C,SU V C,et al. Broadband achromatic optical metasurface devices[J]. Nature Communications,2017,8:187.
[5] NI Xingjie,KILDISHEV A V,SHALAEV V M. Metasurface holograms for visible light[J]. Nature Communications,2013,4:2807.
[6] ZHENG Guoxing,MUHLENBERND H,KENNEY M,et al. Metasurface holograms reaching 80% efficiency[J]. Nature Nanotechnology,2015,10(4):308-312.
[7] KHORASANINEJAD M,ZHU W,CROZIER K B. Efficient polarization beam splitter pixels based on a dielectric metasurface[J]. Optica,2015,2(4):376-382.
[8] 庄亚强,王光明,张小宽,等. 基于梯度超表面的反射型线-圆极化转换器设计[J]. 物理学报,2016,65(15):154102. ZHUANG Yaqiang,WANG Guangming,ZHANG Xiaokuan,et al. Design of reflective linear-circular polarization converter based on phase gradient metasurface[J]. Acta Physica Sinica,2016,65(15):154102.
[9] KHAN M I,FRAZ Q,TAHIR F A. Ultra-wideband cross polarization conversion metasurface insensitive to incidence angle[J]. Journal of Applied Physics,2017,121(4):045103.
[10] YI Xunong,LING Xiaohui,ZHANG Zhiyou,et al. Generation of cylindrical vector vortex beams by two cascaded metasurfaces[J]. Optics Express,2014,22(14):17207-17215.
[11] YUE Fuyong,WEN Dandan,XIN Jingtao,et al. Vector vortex beam generation with a single plasmonic metasurface[J]. ACS Photonics,2016,3(9):1558-1563.
[12] 李瑶,莫伟成,杨振刚,等. 利用超表面天线阵列产生太赫兹涡旋光束[J]. 激光技术,2017,41(5):644-648. LI Yao,MO Weicheng,YANG Zhengang,et al. Generation of terahertz vortex beams base on metasurface antenna array[J]. Laser Technology,2017,41(5):644-648.
[13] ZHANG Jing,MEI Zhonglei,ZHANG Wanru,et al. An ultrathin directional carpet cloak based on generalized Snell's law[J]. Applied Physics Letters,2013,103(15):151115.
[14] HUANG Cheng,YANG Jianing,WU Xiaoyu,et al. Reconfigurable metasurface cloak for dynamical electromagnetic illusions[J]. ACS Photonics,2018,5(5):1718-1725.
[15] YANG Yihao,JING Liqiao,ZHENG Bin,et al. Full-polarization 3D metasurface cloak with preserved amplitude and phase[J]. Advanced Materials,2016,28(32):6866-6871.
[16] XU Hexiu,HU Guangwei,WANG Yanzhao,et al. Polarization-insensitive 3D conformal-skin metasurface cloak[J]. Light:Science & Applications,2021,10(1):75.
[17] YANG Siming,LIU Peng,YANG Mingda,et al. From flexible and stretchable meta-atom to metamaterial:A wearable microwave meta-skin with tunable frequency selective and cloaking effects[J]. Scientific Reports,2016,6:21921.
[18] LI Jiaqi,ZHANG Lei,ZHANG Min,et al. Wearable conformal metasurfaces for polarization division multiplexing[J]. Advanced Optical Materials,2020,8(13):2000068.
[19] 梁庆宣,杨贞,何锦,等. 超材料结构增材制造技术及其应用研究进展[J]. 航空制造技术,2019,62(Z1):30-37,63. LIANG Qingxuan,YANG Zhen,HE Jin,et al. Research Progress of Additive Manufacturing Technology and Its Applications for Metamaterial Structure[J]. Aeronautical Manufacturing Technology,2019,62(Z1):30-37,63.
[20] XIE Yangbo,YE Shengrong,REYES C,et al. Microwave metamaterials made by fused deposition 3D printing of a highly conductive copper-based filament[J]. Applied Physics Letters,2017,110(18):181903.
[21] ADAMS J J,DUOSS E B,MALKOWSKI T F,et al. Conformal printing of electrically small antennas on three-dimensional surfaces[J]. Advanced Materials,2011,23(11):1335-1340.
[22] JIANG Zijie,LIANG Qingxuan,LI Zhaohui,et al. Experimental demonstration of a 3D-printed arched metasurface carpet cloak[J]. Advanced Optical Materials,2019,7(15):1900475.
[23] JIANG Zijie,LIANG Qingxuan,LI Zhaohui,et al. A 3D carpet cloak with non-euclidean metasurfaces[J]. Advanced Optical Materials,2020,8(19):2000827.
[24] 王迪,邓国威,杨永强,等. 金属异质材料增材制造研究进展[J]. 机械工程学报,2021,57(1):186-198. WANG Di,DENG Guowei,YANG Yongqiang,et al. Research progress on additive manufacturing of metallic heterogeneous materials[J]. Journal of Mechanical Engineering,2021,57(1):186-198.
[25] YANG Jianing,HUANG Cheng,WU Xiaoyu,et al. Dual-wavelength carpet cloak using ultrathin metasurface[J]. Advanced Optical Materials,2018,6(14):1800073.