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This study describes the realisation of an advanced waveguide bandpass filter using shaping of the resonator and coupling structures to enhance the radiofrequency performance. Additive manufacturing's inherent geometrical freedom is exploited in these structures. The method of creating a good starting point for optimisation using electro‐magnetic (EM) simulation tools is compared with standard techniques for waveguide filters. A simple filter is given as an example to demonstrate the suitability of the structures and manufacturing techniques followed by a more advanced filter function. Simulations are presented and compared with both measured performance and rectangular waveguide realisations. The advantages and disadvantages of the manufacturing process and complex geometries are discussed.

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