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In this work, the design, fabrication and characterization of micro-air-channel-based unit cells aimed at phase control exploitable in 5G-mmwave applications are reported. The basic unit cell consisted of rectangular dielectric blocks (RDB) placed onto a thin substrate, realized by means of a resin polymer. The RDB effective relative permittivity was changed by tuning specific design parameters and infill density percentage (ID%), that was engineered through the introduction of a number of uniformly distributed micro-air channels. The reflected phase variation was numerically quantified in terms of frequency range and ID%, thus proving that a controlled phase variation can be accomplished depending on air-channel number. The prototypes were fabricated by means of the micro-inverted Stereolithography (SLA). In order to assess the accuracy of the SLA technology on the dimensions imposed by the high aspect ratio of the structures, larger unit cells operating in the X band were first fabricated. The acquired technological know-how has been subsequently exploited to fabricate smaller unit cells operating at mmwave. Geometrical characterizations of the prototypes, performed via a visual system setup, put in evidence the technological challenges, especially faced to realize open micro-air channels. In particular, as smaller micro-channel were actually obtained for some samples, a consequent increase of the actual ID% and effective relative permittivity values was experienced by the related unit cells. Nonetheless, the experimental results performed on the fabricated prototypes in the X band and mmwave range were in good agreement with the numerical ones, confirming the phase variation vs. ID% trends of the simulated unit cell arrays.

3D Printed Micro-Cells for Phase Control in 5G mmWave Applications