This paper introduces the first fully 3-D printed tunable microwave subsystem, consisting of 26 circuit elements. Here, a polymer-based 3-D printed Ku-band 4-element steerable phased-array antenna with fully integrated beam-forming network is demonstrated. Polyjet was adopted for fabricating the main body of the subsystem, as it is capable of producing a geometrically complex structure with high resolution over a large volume. Low-cost fused deposition modeling was chosen to manufacture the dielectric inserts and brackets for the phase shifters. The measured radiation pattern revealed that the phased-array antenna subsystem has total beam steering angles of 54° and 52° at 15 GHz and 17 GHz, respectively. Excellent input return loss behavior was observed across the optimum operational frequency range of 15 to 17 GHz, with a worst-case measured return loss of 12.9 dB. This work clearly shows the potential of using 3-D printing technologies for manufacturing fully integrated subsystems with complex geometric features.
