Single part microwave filters made from selective laser melting

Lorente, José A.; Mendoza, Mónica Martínez; Petersson, Axel Zafra; Pambaguian, Laurent; Melcón, Alejandro Álvarez; Ernst, Christoph

doi:10.23919/eumc.2009.5296127

Cited by 23 publications

(6 citation statements)

References 2 publications

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“…Metal-based printing has also been adopted, with different types of cavity resonator that include: shaped rectangular and slotted spherical at X-band [45]- [46], depressed superellipsoid at Ku-band [47] and rectangular cavity at W-band [48], G-band [49] and J-band [44]. As expected, higher insertion loss is measured, when compared to machined BPFs, due to lower effective bulk DC conductivity and larger surface roughness.…”

Section: Bandpass Filtersmentioning

confidence: 83%

Polymer-Based 3-D Printed 140 to 220 GHz Metal Waveguide Thru Lines, Twist and Filters

et al. 2023

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This paper demonstrates the current state-of-the-art in low-cost, low loss ruggedized polymer-based 3-D printed G-band (140 to 220 GHz) metal-pipe rectangular waveguide (MPRWG) components. From a unique and exhaustive up-to-date literature review, the main limitations for G-band split-block MPRWGs are identified as electromagnetic (EM) radiation leakage, assembly part alignment and manufacturing accuracy. To mitigate against leakage and misalignment, we investigate a 'trough-and-lid' split-block solution. This approach is successfully employed in proof-of-concept thru lines, and in the first polymer-based 3-D printed 90° twist and symmetrical diaphragm inductive iris-coupled bandpass filters (BPFs) operating above 110 GHz. An inexpensive desktop masked stereolithography apparatus 3-D printer and a commercial copper electroplating service are used. Surface roughness losses are calculated and applied to EM (re-)simulations, using two modifications of the Hemispherical model. The 7.4 mm thru line exhibits a measured average dissipative attenuation of only 12.7 dB/m, with rectangular-to-trapezoidal cross-sectional distortion being the main contributor to loss. The 90° twist exhibits commensurate measured performance to its commercial counterpart, despite the much lower manufacturing costs. A detailed time-domain reflectometry analysis of flange quality for the thru lines and 90° twists has also been included. Finally, a new systematic iris corner rounding compensation technique, to correct passband frequency down-shifting is applied to two BPFs. Here, the 175 GHz exemplar exhibits only 0.5% center frequency up-shifting. The trough-and-lid assembly is now a viable solution for new upper-mm-wave MPRWG components. With this technology becoming less expensive and more accurate, higher frequencies and/or more demanding specifications can be implemented.

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Section: Bandpass Filtersmentioning

confidence: 83%

Polymer-Based 3-D Printed 140 to 220 GHz Metal Waveguide Thru Lines, Twist and Filters

et al. 2023

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“…At first, AM technologies have been investigated for the development of stand-alone components relevant to satellite communication payloads, including straight and meander waveguides [47], [48], filters [49], [50], [51], [52], [53], [54], ortho-mode transducers/polarizers [55], [56], [57], [58], [59], and radiating elements, such as helix/quad-ridge antennas [23], [60], [61], and feed horns [57], [62]. Investigations on the multipactor performance of AM components have also been carried out [63].…”

Section: D-printed Components and Rf Front-ends For Space A Stand-alo...mentioning

confidence: 99%

How 3D-Printing Is Changing RF Front-End Design for Space Applications

et al. 2023

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3D-printing is leading to a major transformation in many industrial and application sectors, ranging from medical to aerospace. In the space sector, 3D-printing has firstly been adopted for the development of structural and thermal parts, such as brackets and heat pipes. In more recent years, thanks to improvements in precision and surface roughness, 3D-printing technologies have steadily been investigated also for the development of radio frequency components and advanced payloads. Indeed, the unique features of 3D-printing, including the free-form capability and the ease for customization, make these manufacturing technologies very appealing in the development of complex radio-frequency front-ends for space applications, including New Space constellations and next generation software-defined communication satellites. They also enable a drastic simplification of mechanical designs by reducing the number of interfaces and assembling screws of large radio-frequency front-ends, thus leading to significant mass savings and higher integration. This paper briefly reports on recent advances in 3D-printing that have been carried out according to the current trends in radio-frequency front-ends for satellite communications.

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“…microstrip, coaxial or dielectric), in the mm-wave area the focus usually lies on the waveguide technology. The manufacturing of waveguide components in the lower frequency bands is generally not associated with any difficulties and different manufacturing techniques are available, including the classical computerized numerical control (CNC) milling or versatile 3-D printing approaches [1], [2]. Up to moderate center frequencies, tuning screws might be used to compensate for manufacturing tolerances.…”

Section: Introductionmentioning

confidence: 99%

Quasi-Elliptical Stub-Based Multi-Resonance Waveguide Filters With Low Manufacturing Complexity for mm-Wave Applications

et al. 2023

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In this paper, the design and realization of quasi-elliptical waveguide filters with reduced manufacturing complexity are discussed. The filters are based on TE mode cavities, which are loaded with TM mode stubs. It is shown that dual-, triple-and quadruple-resonance segments are obtained by using up to three stubs loaded on the broad side of a TE mode cavity. The structures obtained can either be used as a stand-alone filter or even as a building block suitable for the realization of higher order filters. The multiresonance blocks reveal several advantages in the mm-wave area: The manufacturing complexity is easy to handle and comparable to simple all-pole filters, which is especially important at high frequencies. Therefore, three prototypes are manufactured as proof of concept in the D-band (110 GHz-170 GHz). Moreover, the building blocks are able to produce n − 1 transmission zeros (TZs) with n being the number of resonances. Therefore, the blocks generate between one (dual-resonance) and up to three (quadruple-resonance) TZs. Advantageously, the filters can be cut in the E-plane in order to reduce the insertion loss and hence consist of only two components. Three examples are manufactured by high precision CNC milling and reveal good agreement to the simulation by obtaining unloaded Q-factors of up to 1000.INDEX TERMS D-band filter, E-plane cut, high precision CNC milling, reduced manufacturing complexity, TM mode stub.

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Single part microwave filters made from selective laser melting

Cited by 23 publications

References 2 publications

Polymer-Based 3-D Printed 140 to 220 GHz Metal Waveguide Thru Lines, Twist and Filters

Polymer-Based 3-D Printed 140 to 220 GHz Metal Waveguide Thru Lines, Twist and Filters

How 3D-Printing Is Changing RF Front-End Design for Space Applications

Quasi-Elliptical Stub-Based Multi-Resonance Waveguide Filters With Low Manufacturing Complexity for mm-Wave Applications

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