Additive manufacturing techniques for meander-line polarizers
Methods, systems, and apparatus, including computer programs encoded on a computer storage medium, for producing meander-line polarizers. In some implementations, a meander-line polarizer includes a dielectric substrate made of a polyester polymer material and meander-line arrays formed on a surface of the dielectric substrate. Each meander-line array includes a sequence of alternating perpendicular conductive traces that are formed the surface of the dielectric substrate by applying conductive ink to the surface of the dielectric substrate using a template that defines a location and dimensions of each conductive trace of each meander-line array.
1. A method for producing a meander-line polarizer, the method being performed by an additive manufacturing device, the method comprising:
receiving, by the additive manufacturing device, a template that defines an arrangement of meander-line arrays for the meander-line polarizer, each of the meander-line arrays including a sequence of alternating perpendicular conductive traces, the template defining dimensions of each conductive trace and a location of each conductive trace in the arrangement;
receiving, by the additive manufacturing device, a dielectric substrate made of a polyester polymer material; and
generating, by the additive manufacturing device and using the template, the meander-line arrays on the surface of the dielectric substrate by applying, for each of the conductive traces, conductive ink from an ink supply for the additive manufacturing device to the surface of the dielectric substrate in the location for the conductive trace defined by the template and with the dimensions for the conductive trace defined by the template.
2. The method of claim 1 , wherein receiving the dielectric substrate made of the polyester polymer material comprises receiving a dielectric substrate made of polyethylene terephthalate (PET).
3. The method of claim 1 , wherein:
the template comprises a screen that includes an aperture for each of the meander-line arrays, wherein the apertures for the meander-line arrays are located in the screen at respective locations defined by the template; and
applying, for each of the conductive traces, conductive ink to the surface of the dielectric substrate comprises:
placing the screen over the surface of the dielectric substrate; and
applying the conductive ink over the screen.
4. The method of claim 3 , wherein applying, for each conductive trace, conductive ink to the surface of the dielectric substrate comprises spreading the conductive ink across the screen and into the apertures.
5. The method of claim 4 , wherein spreading the conductive ink across the screen and into the apertures comprises moving a scraper over the screen from a first side of the screen to a second side of the screen opposite the first side of the screen.
6. The method of claim 5 , wherein:
the additive manufacturing device is a screen printing device; and
receiving, by the additive manufacturing device, a dielectric substrate made of a polyester polymer material comprises receiving a portion of a roll of the dielectric substrate.
7. The method of claim 1 , further comprising:
determining that a particular conductive trace of a particular meander-line array applied to the surface of the dielectric substrate has a width that is greater than a maximum width for the particular conductive trace defined by the template; and
removing, using etching or a laser, at least a portion of the particular conductive trace such that the width of the particular trace is equal to or less than the maximum width.
8. The method of claim 1 , wherein the conductive ink comprises one of conductive copper ink or conductive silver ink.
9. The method of claim 1 , wherein applying, for each conductive trace, conductive ink to the surface of the dielectric substrate comprises applying, by an inkjet printer, the conductive ink for each conductive trace in a location on the surface of the dielectric substrate defined by the template.