A phased array antenna differs from a conventional antenna, such as a dish antenna, in that it coherently adds radiation from multiple radiating elements instead of mechanical positioning to direct RF energy. When transmitting and receiving information from a source while in motion, a phased array antenna can continuously adjust its signal to focus on the source. New antenna designs focus on integrating phased array antennas into the structure of the antenna platform, as advanced antenna platforms require the antenna to take up less and less real estate. With further development of phased array antennas, new designs become increasingly complex. The manufacturing techniques to facilitate the integration of complex antenna designs into the structure of an antenna platform must be developed, as traditional manufacturing operations, such as injection molding, machining and bulk deformation processes, are not well suited to create the small details and complex three dimensional lattice designs of the antennas. Innovative solutions need to be developed that allow the manufacture of complex antennas, thereby enabling testing to be performed on actual devices. The results from testing physical models can buttress analytical models and lead to better antenna designs. This work developed and studied suitable methods for manufacturing three-dimensional, structurally-integrated antennas.

In this thesis we identify device (3D Microelectrode Arrays – 3D MEAs)/system (commercial electronics interface) issues preventing the scaling up of the world’s first in vitro model of afferent synaptic signaling in the spinal cord and develop a potential solution involving spin cast insulation and micromilled/microdrilled/microsoldered/flex circuit integrated 6-well interface board with connectors for analyzing up to six 3D MEAs simultaneously at one time. These novel advances can scale experimentation in the development of new treatments, pharmacological responses, and other electrophysiological discoveries for neurological disorders. In addition, we report on a multi-material palette towards the microfabrication of the aforementioned 3D Microelectrodes Arrays for integration with a variety of 3D electrogenic Microphysiological Systems (MPS) beyond the afferent synaptic model. The goal of this part of the thesis was to fabricate 3D MEAs with six microelectrodes by utilizing materials such as polycarbonate (PC), polymethyl methacrylate (PMMA), and polysulfone (PS). We created a reliable microfabrication process by combining laser micromachining, laser-induced breakdown spectroscopy (LIBS), 3D needle assembly, SU-8 coatings and micromilling/ microdrilling techniques. The 3D MEAs demonstrate impedance characteristics similar to commercial MEAs. Additionally, all material combinations showed outstanding transparency and biocompatibility for applicability in 3D neuronal and cardiac studies.