Lightweight frequency selective surface prototypes based on MXene-coated 3D-printed dielectric structures

Conventional methods for fabricating frequency selective surfaces (FSSs), such as photolithography and metal deposition, typically require rigid substrates and high-cost equipment, thereby limiting scalability and design flexibility. As a promising alternative, 3D printing enables rapid and lightweight prototyping of geometrically complex FSSs using polymeric materials; however, their inherently poor electrical conductivity restricts their direct application in high-frequency regimes. In this study, we present a hybrid fabrication strategy that combines stereolithographic (SLA) 3D printing with dip-coating using Ti₃C₂T_x MXene, enabling the production of structurally robust and electrically conductive FSSs without the need for conventional metallisation. A hexagonal Y-slot bandpass FSS was fabricated using five dip-coating cycles, achieving a 99% reduction in weight compared to a copper-coated weights, while retaining excellent electromagnetic performance, featuring a resonance at 11.2 GHz, an insertion loss of 0.743 dB, and a return loss of 21.1 dB. The proposed method offers a scalable and cost-effective route for realising lightweight FSSs and demonstrates significant potential for integration into weight-sensitive electromagnetic platforms such as satellites, unmanned aerial vehicles, and aerospace radomes.