220–325GHz All-Photopolymer Bragg Horn Antennas Towards Eco-Friendly Terahertz Applications

This paper presents the development of the world’s first high-gain, all-photopolymer Bragg horn antennas explicitly designed for the WR-3.4 band (220–325GHz), marking a groundbreaking advancement in terahertz (THz) antenna technology. Unlike conventional metallic horn antennas, which suffer from conductor losses and manufacturing complexity, this innovative design utilizes eco-friendly photopolymer materials and additive manufacturing, achieving a fractional bandwidth of 38.5% that fully covers the WR-3.4 band. The proposed antenna achieves a measured peak gain of 28.98 dBi at 300GHz, with a return loss better than − 20dB across the band and a consistent half-power beamwidth (HPBW) of ~ 5°, ensuring precise directivity and minimal sidelobe interference. By employing a novel horn-type adapter for seamless mode conversion from TE ₁₀ to the fundamental HE ₁₁ mode, the design significantly enhances coupling efficiency and reduces signal loss. Additionally, fabrication costs can be reduced by over 50% compared to traditional metallic designs, while maintaining repeatability and enabling rapid prototyping. As the first demonstration of photopolymer-based antennas achieving such high gains in the 220-325GHz THz spectrum, this work establishes a new benchmark in THz antenna technology, providing an eco-friendly, cost-effective, and high-performance solution for high-speed communication, medical diagnostics, security imaging, and spectroscopy applications.