In this contribution the design process for hot embossed millimeter-wave antennas integrated in plastic multilayer car body panels is presented. Starting from material characteristics and fixed parameters obtained by the investigation of the fabrication process steps, the design of a microstrip patch antenna working at 24GHz will be demonstrated. The antenna is embedded within a plastic multi-layer structure by laminating the substrate layer with a paint foil and reinforcing the part by back injection molding. The comparison between simulation and measurement results will give information about the producibility of conformal integrated antennas for automotive radar applications like pre-crash detection or parking aid.
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