The notch filter plays a crucial role as a protective
component in microwave diagnostics, primarily by addressing issues
related to catastrophic interference. Designed for millimeter-wave
diagnostics on the stellarator Wendelstein 7-X (W7-X), a WR-6
waveguide-based notch filter has been successfully developed to
effectively isolate leakage from auxiliary heating gyrotrons
operating at 140 GHz. The filter incorporates cylindrical cavities
resonating at 140 GHz for the TE11p mode, with coupling
structures that are designed and optimized for high-efficiency
coupling. This configuration simplifies fabrication, thereby
ensuring high-yield production. Experimental fabrication and
in-house characterization confirm the notch filter's exceptional
performance, with over 60 dB rejection in the vicinity of 140 GHz
and low insertion loss (< 2 dB) above and below the notch
frequency across a broad frequency bandwidth (121–138 GHz,
142–163 GHz). The utilization of this high-frequency structure
fabrication technology can be applied to millimeter-wave diagnostics
on other machines. In addition to the design elements of the notch
filter, this paper also provides a detailed discussion of the
fabrication process and methodology.