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This paper first reviews manufacturing technologies for realizing air-filled metal-pipe rectangular waveguides (MPRWGs) and 3-D printing for microwave and millimeter-wave applications. Then, 3-D printed MPRWGs are investigated in detail. Two very different 3-D printing technologies have been considered: low-cost lower-resolution fused deposition modeling for microwave applications and higher-cost high-resolution stereolithography for millimeter-wave applications. Measurements against traceable standards in MPRWGs were performed by the U.K.'s National Physical Laboratory. It was found that the performance of the 3-D printed MPRWGs were comparable with those of standard waveguides. For example, across X-band (8-12 GHz), the dissipative attenuation ranges between 0.2 and 0.6 dB/m, with a worst case return loss of 32 dB; at W-band (75-110 GHz), the dissipative attenuation was 11 dB/m at the band edges, with a worst case return loss of 19 dB. Finally, a high-performance W-band sixth-order inductive iris bandpass filter, having a center frequency of 107.2 GHz and a 6.8-GHz bandwidth, was demonstrated. The measured insertion loss of the complete structure (filter, feed sections, and flanges) was only 0.95 dB at center frequency, giving an unloaded quality factor of 152-clearly demonstrating the potential of this low-cost manufacturing technology, offering the advantages of lightweight rapid prototyping/manufacturing and relatively very low cost when compared with traditional (micro)machining.

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Over time, the accuracy and speed by which a material can be characterized should improve. Today, the Nicolson-Ross-Weir (NRW) methodology represents a well-established method for extracting complex dielectric properties at microwave frequencies, with the use of a modern vector network analyzer. However, as will be seen, this approach suffers from three fundamental limitations to accuracy. Challenging NRW methods requires a methodical and robust investigation. To this end, using a dielectric-filled metal-pipe rectangular waveguide, five independent approaches are employed to accurately characterize the sample at the Fabry-Pérot resonance frequency (non-frequency dispersive modeling). In addition, manual Graphical and automated Renormalization spectroscopic approaches are introduced for the first time in the waveguide. The results from these various modeling strategies are then compared and contrasted to NRW approaches. As a timely exemplar, 3-D printed acrylonitrile-butadiene-styrene (ABS) samples are characterized and the results are compared with existing data available in the open literature. It is found that the various Fabry-Pérot resonance model results all agree with one another and validate the two new spectroscopic approaches; in doing so, exposing three limitations of the NRW methods. It is also shown that extracted dielectric properties for ABS differ from previously reported results and reasons for this are discussed. From measurement noise resilience analysis, a methodology is presented for determining the upper bound signal-to-noise ratio for the vector network analyzer (not normally associated with such instrumentation). Finally, fused deposition modeling (FDM) 3-D printing can result in a non-homogeneous sample that excites open-box mode resonances. This phenomenon is investigated for the first time analytically and with various modeling strategies.

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