Abstract This study presents a comprehensive framework for the development and evaluation of radar-absorbing materials (RAMs) by combining optimized composite formulation with additive manufacturing strategies. Unlike many existing studies that remain largely theoretical or rely on flat, fully dense printed plates, the proposed approach introduces an application-oriented framework that integrates material selection, process optimization, and three-dimensional geometry. Initial specimens were prepared via conventional thermoplastic processing and compression molding, allowing detailed rheological, thermomechanical, and microstructural characterizations. These rheological insights were further employed as predictive indicators of FDM printability, enabling defect-free filament extrusion and geometric stability during fabrication. These insights were then used to guide and optimize 3D printing parameters, aiming to replicate or exceed the performance of molded references through lightweight, geometrically adaptable structures. Electromagnetic properties were first assessed using coaxial airline measurements in the X-band to optimize filler content and absorber thickness selection, and then validated through free-space antenna tests. Finally, antenna-based measurements were used to investigate the effects of geometric parameters such as pyramid height and infill ratio on absorption performance. Among 3D-printed structures, Concentric infill best matched the performance of compression-molded references. FS‑20 pyramidal absorber (20 mm base) geometries enabled broadband absorption ( RL < − 10 dB, 9–12.5 GHz). Infill reduction from 100 to 30% provided a 58% weight saving while preserving deep RL dips (≈ − 25 dB) and bandwidth. Overall, this study establishes a quantitatively validated material–process–geometry integration strategy that enables simultaneous broadband absorption and substantial weight reduction, offering a scalable and application-ready pathway beyond conventional flat or fully dense RAM designs.
Yurtbasi et al. (Sun,) studied this question.