The need for miniaturized, and high performance microwave devices has focused significant attention onto new fabrication technologies that can simultaneously achieve high performance and low manufacturing complexity. Additive manufacturing (AM) has proven its capability in fabricating high performance, compact and light weight microwave circuits and antennas, as well as the ability to achieve designs that are complicated to fabricate using other manufacturing approaches. Direct print additive manufacturing (DPAM) is an emerging AM process that combines the fused deposition modeling (FDM) of thermoplastics with micro-dispensing of conductive and insulating pastes. DPAM has the potential to jointly combine high performance and low manufacturing complexity, along with the possibility of real-time tuning. This dissertation aims to leverage the powerful capabilities of DPAM to come-up with new designs and solutions that meet the requirements of rapidly evolving wireless systems and applications. Furthermore, the work in this dissertation provides new techniques and approaches to alleviate the drawbacks and limitations of DPAM fabrication technology. Firstly, the development of 3D packaged antenna, and antenna array are presented along with an analysis of the inherent roughness of 3D printed structures to provide a deeper understanding of the antenna RF performance. The single element presents a new volumetric approach to realizing a 3D half-wave dipole in a packaged format, where it provides the ability to keep a signal distribution network in close proximity to the ground plane, facilitating the implementation of ground connections (e.g. for an active device), mitigating potential surface wave losses, as well as achieving a modest (10.6%) length reduction. In addition, a new approach of implementing conformal antennas using DPAM is presented by printing thin and flexible substrate that can be adhered to 3D structures to facilitate the fabrication and reduce the surface roughness. The array design leverages direct digital manufacturing (DDM) technology to realize a shaped substrate structure that is used to control the array beamwidth. The non-planar substrate allows the element spacing to be changed without affecting the length of the feed network or the distance to the underlying ground plane. The second part describes the first high-Q capacitively-loaded cavity resonator and filter that is compatible with direct print additive manufacturing. The presented design is a compromise between quality factor, cost and manufacturing complexity and to the best of our knowledge is the highest Q-factor resonator demonstrated to date using DPAM compatible materials and processes. The final version of the single resonator achieves a measured unloaded quality factor of 200-325 over the frequency range from 2.0 to 6.5 GHz. The two pole filter is designed using a coupled-resonator approach to operate at 2.44 GHz with 1.9% fractional bandwidth. The presented design approach simplifies evanescent-mode filter fabrication, eliminating the need for micromachining and vias, and achieving a total weight of 1.97 g. The design is fabricated to provide a proof-of-principle for the high-Q resonator and filter that compromises between performance, cost, size, and complexity. A stacked version of the two-pole filter is presented to provide a novel design for multi-layer embedded applications. The fabrication is performed using an nScrypt Tabletop 3Dn printer. Acrylonitrile Butadiene Styrene (ABS) (relative permittivity of 2.7 and loss tangent of 0.008) is deposited using fused deposition modeling to form the antenna, array, resonator, and filter structures, and Dupont CB028 silver paste is used to form the conductive traces conductive regions (the paste is dried at 90 °C for 60 minutes, achieving a bulk DC conductivity of 1.5×106 S/m.). A 1064 nm pulsed picosecond Nd:YAG laser is used to laser machine the resonator and filter input and output feedlines.

The demand for high power density keeps driving the development of electromagnetic integration technologies in the field of power electronics. Based on planar homogeneous integrated structures, the mechanism of the electromagnetic integration of passives has been investigated with distributed-parameter models. High order modeling of integrated passives has been developed to investigate the electromagnetic performance. The design algorithm combining electromagnetic design and loss models has been developed to optimize and evaluate the spiral winding structure. High power density of 480 W/in3 has been obtained on the prototype. Due to the structural limitation, the currently applied planar spiral winding structure does not sufficiently utilize the space, and the structure is mechanically vulnerable. The improvement on structures is necessary for further application of integrated passives. The goal of this research is to investigate and evaluate alternative structures for high-power-density integrated passives. The research covers electromagnetic modeling, constructional study, design algorithm, loss modeling, thermal management and implementation technology The symmetric single layer structure and the stacked structure are proposed to overcome the disadvantages of the currently applied planar spiral winding structure. Because of the potential of high power density and low power loss, the stacked structure is selected for further research. The structural characteristics and the processing technologies are addressed. By taking an integrated LLCT module as the study case, the general design algorithm is developed to find out a set of feasible designs. The obtained design maps are used to evaluate the constraints from spatial, materials and processing technologies for the stacked structure. Based on the assumption of one-dimensional magnetic filed on the cross-section and linear current distribution along the longitudinal direction of the stacked structure, the electromagnetic field distribution is analyzed and the loss modeling is made. The experimental method is proposed to measure the loss and to verify the calculation. The power loss in the module leads to thermal issues, which limit the processed power of power electronics modules and thus limit the power density. To further improve the power handling ability of the module, the thermal management is made based on loss estimation. The heat extraction technology is developed to improve the heat removal ability and further improve the power density of integrated passives. The experimental results verify the power density improvement from the proposed stacked structure and the applied heat extraction technology. The power density of 1147 W/in3 (70 W/cm3) is achieved in the implemented LLCT module with the efficiency of 97.8% at output power of 1008W. / Ph. D.

Lithium ion batteries (LIBs) have attracted considerable interest due to their wide range of applications, such as portable electronics, electric vehicles (EVs) and aerospace applications. Particularly, the emergence of a variety of nanostructured materials has driven the development of LIBs towards the next generation, which is featured with high specific energy and large power density. Herein, rolled-up nanotechnology is introduced for the design of strain-released materials as anodes of LIBs. Upon this approach, self-rolled nanostructures can be elegantly combined with different functional materials and form a tubular shape by relaxing the intrinsic strain, thus allowing for enhanced tolerance towards stress cracking. In addition, the hollow tube center efficiently facilitates electrolyte mass flow and accommodates volume variation during cycling. In this context, such structures are promising candidates for electrode materials of LIBs to potentially address their intrinsic issues. This work focuses on the development of superior structures of Si and SnO2 for LIBs based on the rolled-up nanotech. Specifically, Si is the most promising substitute for graphite anodes due to its abundance and high theoretical gravimetric capacity. Combined with the C material, a Si/C self-wound nanomembrane structure is firstly realized. Benefiting from a strain-released tubular shape, the bilayer self-rolled structures exhibit an enhanced electrochemical behavior over commercial Si microparticles. Remarkably, this behavior is further improved by introducing a double-sided carbon coating to form a C/Si/C self-rolled structure. With SnO2 as active material, an intriguing sandwich-stacked structure is studied. Furthermore, this novel structure, with a minimized strain energy due to strain release, exposes more active sites for the electrochemical reactions, and also provides additional channels for fast ion diffusion and electron transport. The electrochemical characterization and morphology evolution reveal the excellent cycling performance and stability of such structures.

Lithium ion batteries (LIBs) have attracted considerable interest due to their wide range of applications, such as portable electronics, electric vehicles (EVs) and aerospace applications. Particularly, the emergence of a variety of nanostructured materials has driven the development of LIBs towards the next generation, which is featured with high specific energy and large power density. Herein, rolled-up nanotechnology is introduced for the design of strain-released materials as anodes of LIBs. Upon this approach, self-rolled nanostructures can be elegantly combined with different functional materials and form a tubular shape by relaxing the intrinsic strain, thus allowing for enhanced tolerance towards stress cracking. In addition, the hollow tube center efficiently facilitates electrolyte mass flow and accommodates volume variation during cycling. In this context, such structures are promising candidates for electrode materials of LIBs to potentially address their intrinsic issues. This work focuses on the development of superior structures of Si and SnO2 for LIBs based on the rolled-up nanotech. Specifically, Si is the most promising substitute for graphite anodes due to its abundance and high theoretical gravimetric capacity. Combined with the C material, a Si/C self-wound nanomembrane structure is firstly realized. Benefiting from a strain-released tubular shape, the bilayer self-rolled structures exhibit an enhanced electrochemical behavior over commercial Si microparticles. Remarkably, this behavior is further improved by introducing a double-sided carbon coating to form a C/Si/C self-rolled structure. With SnO2 as active material, an intriguing sandwich-stacked structure is studied. Furthermore, this novel structure, with a minimized strain energy due to strain release, exposes more active sites for the electrochemical reactions, and also provides additional channels for fast ion diffusion and electron transport. The electrochemical characterization and morphology evolution reveal the excellent cycling performance and stability of such structures.