Metallic 3D Printed Rectangular Waveguides (WR3) for Rapid Prototyping of THz Packages

Makhlouf, Sumer; Khani, Besher; Lackmann, Jörg; Dulme, Sebastian; Stöhr, A.

doi:10.1109/iwmts.2018.8454684

Cited by 8 publications

(3 citation statements)

References 16 publications

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“…To make these printed waveguides electrically conductive, multiple methods have been used. Most research has focused on directly printing the waveguides with metals using selective laser melting (SLM) (Zhang and Zirath, 2016; Makhlouf et al , 2018; Booth and Lluch, 2017; Addamo et al , 2018) and binder jetting (Rojas-Nastrucci et al , 2017), or depositing metal films on the waveguides using a combination of sputtering, electroless plating and electroplating (Tomassoni and Bozzi, 2020; Li et al , 2017; Delmonte et al , 2022; D’Auria et al , 2015; Ghazali et al , 2017). However, these options can be just as expensive in terms of time and material as the waveguides they are intending to replace.…”

Section: Introductionmentioning

confidence: 99%

Additively manufactured rectangular waveguides for the electromagnetic characterization of materials using the transmission/reflection line method

Smith,

Julius,

Arbeeny

et al. 2023

RPJ

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Purpose Radio frequency (RF) technology relies on the electromagnetic properties of the materials used, which includes their complex permittivities and loss tangents. To measure these properties, techniques for material characterization such as the transmission/reflection method are used in conjunction with conversion techniques to calculate these values from scattering parameters. Unfortunately, these techniques rely on relatively expensive rectangular waveguide adaptors and components, especially if testing over large frequency ranges. This paper aims to overcome this challenge by developing a more affordable test equipment solution based on additively manufactured waveguide sections. Design/methodology/approach To evaluate the effectiveness of using additively manufactured waveguides to perform electromagnetic characterization with the transmission/reflection method, samples of PLA Tough with varying infill percentages and samples made from several Formlabs photopolymer resins are fabricated and analyzed. Findings Results show that the method yielded permittivity and loss tangent values for the measured materials that generally agree with those found in the literature, supporting its credibility. Originality/value The accessibility of this measurement technique will ideally allow for more electromagnetic material characterization to occur and expand the possible use of additive manufacturing in future RF designs. This work also provides characterization of several Formlabs photopolymer resins, which have not been widely analyzed in the current literature.

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Section: Introductionmentioning

confidence: 99%

Additively manufactured rectangular waveguides for the electromagnetic characterization of materials using the transmission/reflection line method

Smith,

Julius,

Arbeeny

et al. 2023

RPJ

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“…At present, the advanced micromachining technology that can fabricate terahertz rectangular waveguides mainly includes high-speed milling, precision electrical discharge machining (EDM), 3D printing, the laser micromachining technique, UV-LIGA [ 8 , 9 , 10 ] and deep reactive ion etching (DRIE) [ 11 , 12 , 13 ] Sumer Makhlouf fabricated a WR3 rectangular waveguide (operating at 230–320 GHz) using metallic laser beam melting (LBM) 3D printing, with the average surface roughness of 2 µm and THz insertion loss of 0.3 dB/mm [ 14 ]. Gagan Kumar designed, fabricated and characterized a planar THz waveguide technology based on a 1D array of periodically spaced blind holes made using standard laser micromachining techniques [ 15 ].…”

Section: Introductionmentioning

confidence: 99%

Terahertz Rectangular Waveguides by UV-LIGA with Megasonic Agitation

Wang

et al. 2022

Micromachines

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This paper researches the fabrication of a WR2.8 terahertz rectangular waveguide operating at the frequency ranging from 260 GHz to 400 GHz via UV-LIGA technology (UV-lithography, electroplating, and molding). In the process, megasonic agitation is applied to improve the mechanical properties and internal surface roughness of the WR2.8 rectangular waveguide. The effects of process parameters on the properties of structures are discussed, and optimized parameters are obtained to achieve accurate geometry dimensions. In addition, the highly crosslinked SU-8 is reliably removed from structures without damage through a synthesis method. The accuracy of the height and width of the WR2.8 rectangular waveguide is 5 µm and 2 µm, respectively, and the measured internal surface roughness is 79.6 nm. Moreover, experimental measurements and numerical simulations of the waveguide are conducted, and the difference between the two is also highlighted.

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“…based on rectangular-, circular-, or ridge waveguide guided-wave media) of the RF systems are manufactured as split-blocks of plastic-/resin-based parts [3][4][5][6][7][8][9][10] or as fully metallic sintered blocks [11][12][13][14][15][16][17]. Metal-based AM processes such as direct metal laser sintering (DMLS) [11], selective laser sintering/melting [12][13][14][15], binder jetting [16], and electron beam melting (EBM) [17] facilitate the realization of RF components with high mechanical strength and are potentially suitable for monolithic integration. However, they are expensive and result in high surface roughness, limiting their applicability to low-frequency RF applications.…”

Section: Introductionmentioning

confidence: 99%

Monolithically-integrated 3D printed coaxial bandpass filters and RF diplexers: single-band and dual-band

Zhao

Psychogiou

2021

Int. J. Microw. Wireless Technol.

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The manuscript reports on additively-manufactured (AM) coaxial-resonator-based bandpass filters (BPFs) and RF diplexers. A monolithic integration concept using stereolithography apparatus (SLA) is proposed and discussed in detail. Coupled-resonator-based synthesis alongside full-electromagnetic-based design methods is used for the design of the monolithic filters and RF diplexers. In particular, the paper discusses a new external coupling mechanism for dual-band BPFs that allow to independently control the coupling in each of the BPF passbands. Furthermore, a novel coaxial transmission line-type T-junction is proposed for the design of single- and dual-band RF diplexers. For practical validation purposes, multiple BPF and RF diplexer prototypes were designed, manufactured and tested at S- and C-band demonstrating the applicability of the proposed concept to low-cost, low-loss and low-weight RF components with complex geometrical features.

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Metallic 3D Printed Rectangular Waveguides (WR3) for Rapid Prototyping of THz Packages

Cited by 8 publications

References 16 publications

Additively manufactured rectangular waveguides for the electromagnetic characterization of materials using the transmission/reflection line method

Additively manufactured rectangular waveguides for the electromagnetic characterization of materials using the transmission/reflection line method

Terahertz Rectangular Waveguides by UV-LIGA with Megasonic Agitation

Monolithically-integrated 3D printed coaxial bandpass filters and RF diplexers: single-band and dual-band

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