Integration of an [Formula Omitted]-Plane Bend, a Twist, and a Filter in Ku/K-Band Through Additive Manufacturing

• Published in: IEEE transactions on microwave theory and techniques 2018-01, Vol.66 (5), p.2210
• Main Authors: Peverini, O A, Lumia, M, Addamo, Giuseppe, Paonessa, F, Virone, G, Tascone, R, Calignano, F, Cattano, G, Manfredi, D
• Format: Article
• Language: English
• Subjects: Additive manufacturing; Aluminum; Free form; Laser beam melting; Machining; Miniaturization; Subsystems; Three dimensional printing; Twisting
• ISSN: 0018-9480; 1557-9670
• DOI: 10.1109/TMTT.2018.2809505

Additive manufacturing technologies have been increasingly applied to the development of radio frequency components in the past few years. Indeed, the free-form capability of these processes allows for the design of novel components, whose actual implementation through conventional machining is rather complex or even not possible. This paper describes a monolithic WR51 component integrating three radio frequency functionalities, namely, bending, twisting, and filtering. Three aluminum prototypes with different bending/twisting radii have been manufactured through the selective laser melting process. They exhibit a measured rejection higher than 60 dB in 17.5 and 21.2 GHz, and a measured return loss better than 20 dB in 12.5 and 15 GHz. Significant mass and envelope reductions (higher than 60% depending on the bending/twisting radius) with respect to the reference subsystem with distinct waveguide components are achieved. These results assess the effectiveness of 3-D metal printing in the miniaturization and integration of waveguide systems.