Microwave absorption optimization via additive manufacturing: Process-dependent mechanisms of electromagnetic attenuation

Additive manufacturing, with its capability to fabricate intricate structures, enables manipulation of electromagnetic wave propagation at the macroscopic level, thus demonstrating significant potential for achieving broader bandwidth and deeper microwave absorption. However, the performance of additively manufactured components is influenced by a combination of different process parameters, and currently, there is a lack of research on the mechanisms of additive manufacturing process parameters on microwave absorption characteristics. Therefore, 27 sets of gradient process parameters were designed and applied to fabricate PA6/CF composite waveguide samples, aiming to investigate the mechanisms of Fused Deposition Modeling process parameters on microwave absorption characteristics. The results demonstrated that process parameters such as layer thickness, printing speed, printing density, and printing temperature significantly influenced the microstructure and microscopic defects distribution of the components. By intelligently optimizing the additive manufacturing process, the microstructure can be further controlled, enabling the customized design of electromagnetic parameters and simultaneously enhancing both the absorption depth and the effective absorption bandwidth. This analysis of the process-dependent mechanisms of electromagnetic attenuation not only expands the application of additive manufacturing in stealth technology but also provides valuable insights for optimizing manufacturing processes and enhancing component quality.