Waveguide components for space applications manufactured by additive manufacturing technology

Abstract

This study investigates the use of novel manufacturing technologies for space antenna feed chain systems. A comparison between conventional and advanced manufacturing technologies concerning the radio‐frequency (RF) performance was made, in order to derive design rules for the novel manufacturing technology. Waveguide runs as well as feed chain components were redesigned by using these design rules. Therefore, mainly elliptical and circular waveguide sections were used. Different components were combined to save mass and power losses. Additive layer manufacturing (ALM) was chosen to build feed chain components in order to investigate the advantages of ALM compared to conventional technologies. This study concludes with an outlook on future opportunities of advanced manufacturing technologies for RF space applications as well as ongoing development activities.

Electromagnetic performance of Ti6Al4V and AlSi7Mg0.6 waveguides with laser beam melting (LBM) produced and abrasive flow machining (AFM) finished internal surfaces

“…Aluminum (AlSi7Mg0.6) and titanium (Ti6Al4V) rectangular waveguides were fabricated with additive manufacturing. Their transmission losses were found to be two times higher than simulated values at X-band (8-12 GHz) and Ka-band (27)(28)(29)(30)(31)(32)(33)(34)(35)(36)(37)(38)(39)(40) [1,2]. For a copper (CuSn15) rectangular waveguide fabricated with AM, its transmission loss at the V-band (40-75 GHz) was four times bigger than that produced by machining [3].…”

“…For a copper (CuSn15) rectangular waveguide fabricated with AM, its transmission loss at the V-band (40-75 GHz) was four times bigger than that produced by machining [3]. Similar transmission losses at X-band (8)(9)(10)(11)(12)) and E-band (60-90 GHz) were also observed in more complex waveguide shapes fabricated by AM [1,2].…”

“…A number of studies [1][2][3][4][5][6][7][8][9] have been dedicated to assess the electromagnetic performances of passive microwave waveguide components produced by AM. The transmission performance of rectangular waveguides, which have been manufactured by conventional manufacturing processes, were investigated.…”

Metal Additive Manufacturing for Satellites and Rockets

“…These complex design requirements suggest the use of additive manufacturing. Kilian et al compared conventional and additive manufacturing of waveguides and radio frequency (RF) components, combining different components to reduce mass and power loss [94]. They found elliptical cross-sections to be advantageous for waveguides, with lower losses as compared to conventional rectangular waveguides.…”

3D Printing of a Monolithic K/Ka-Band Dual-Circular Polarization Antenna-Feeding Network

“…In the microwave field, additive manufacturing technologies have already proved to be viable solutions for the development of waveguide components exhibiting improvements in terms of performance, mechanical complexity, mass, and envelope. Among the others, single waveguide components manufactured through stereo-lithography and selective laser melting are leaky-wave antennas [1], waveguide transitions [2], [3], ortho-mode transducers and polarizers [4], [5], waveguide circuitry [6]- [8], filters [9]- [12], lightweight perforated structures [13]. The main advantage of additive manufacturing technologies is the integration of several radio-frequency functionalities (including radiation, phaseshifting, polarization and frequency diplexing) in a single mechanical part.…”