A study of additive manufacturing technologies and metallizing techniques for microwave waveguide components

Jafferson, J.M.; Vinu, Haridh; Sekaran, K. Chandra

doi:10.1016/j.matpr.2021.02.420

Cited by 6 publications

(7 citation statements)

References 22 publications

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“…4 for the all-pole Chebyshev function taken as example. The frequency responses are given in the Richards' transform domain (in the frequency axis t = j ), and in the natural frequency domain (as a function of the electrical length of the commensurate lines, θ), with both frequency axes related through (4). Additionally, they are related to the normalized frequency response of Fig.…”

Section: Commensurate-line Distributed Ue Prototypementioning

confidence: 99%

“…A DDITIVE manufacturing (AM) was developed in the 1980s to be employed in a large number of applications. Several manufacturing technologies can be included within the AM category, where the main distinctive feature is to build the objects by adding material (layer by layer) instead of machining raw material blocks in a subtractive process [such as the widely used computer numerical control (CNC) milling] [1], [2], [3], [4].…”

Section: Introductionmentioning

confidence: 99%

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Synthesis of Rectangular Waveguide Filters With Smooth Profile Oriented to Direct Metal Additive Manufacturing

Percaz

Hussain

Arregui

et al. 2023

IEEE Trans. Microwave Theory Techn.

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In this article, a novel design method for rectangular waveguide filters intended for fabrication using direct metal additive manufacturing (AM) is proposed. The synthesized filters will feature a smooth profile that allows us to fabricate them orienting the filter propagation axis in the vertical building direction, achieving an optimum configuration for direct metal AM fabrication. The novel design method is valid for any all-pole transfer function, which is initially implemented with a commensurate-line distributed unit element prototype. The impulse response of that initial prototype is then properly interpolated to obtain the target response for a smooth-profiled filter with similar length and profile excursion. Finally, the target impulse response just generated is implemented in the rectangular waveguide technology employing a novel inverse scattering synthesis technique that relies on the coupled-mode theory to model the electromagnetic behavior of the waveguide filter. The novel inverse scattering synthesis technique is general and also valid for the case of filters with very high rejection levels, which is of great relevance in rectangular waveguide technology. A Ku-band low-pass filter with stringent satellite specifications is designed using the proposed method, fabricated by means of a direct metal AM technique, and measured with a vector network analyzer. A very good agreement is achieved between the simulated and measured results, fulfilling the required specifications and demonstrating the feasibility and performance of the novel design method.

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Section: Commensurate-line Distributed Ue Prototypementioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Synthesis of Rectangular Waveguide Filters With Smooth Profile Oriented to Direct Metal Additive Manufacturing

Percaz

Hussain

Arregui

et al. 2023

IEEE Trans. Microwave Theory Techn.

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“…where S(r) is a periodic function with the same periodicity as the crystal and β is the Bloch vector [equivalent to the wave vector k as in (1)]. Due to the now periodic (inhomogeneous) nature of the medium the wave is propagating in, there is no simple solution for the dispersion relationship as for the homogeneous media in (2). Solutions need to be found by solving the wave equation…”

Section: A Necessity Of Broadband Modelingmentioning

confidence: 99%

“…freedom offered by AM to design and manufacture new microwave components [1], [2]. Due to the cumbersome process of metalizing 3-D printed parts [3] and the large cost and bad surface quality of additive manufactured metal [4], many researchers have investigated all-dielectric approaches to create high-frequency devices.…”

mentioning

confidence: 99%

Broadband Effective Permittivity Simulation and Measurement Techniques for 3-D-Printed Dielectric Crystals

Hehenberger

Caizzone

Thurner

et al. 2023

IEEE Trans. Microwave Theory Techn.

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Frequency-dependent dielectric properties of 3-D-printed structured dielectrics (dielectric crystals) with engineered effective permittivity for micro-and mmWave applications are studied. Different modeling and measurement techniques for broadband dielectric properties of such 3-D-printed crystals are reviewed, their tradeoffs discussed, and individual results compared. Numerically obtained results from the plane wave expansion method (PWEM) and Floquet port scattering are compared with traveling-wave measurements in both guided and free-space setups. Furthermore, the shortcomings of effective media theories (EMTs) and resonance measurement methods are addressed and contrasted against broadband methods. Individual simulation and measurement setups are reviewed with respect to dielectric crystals with simple cubic (SC) and face-centered cubic (FCC) symmetry, with different unit cell sizes and volumetric infill fractions. Extracted effective permittivity values from PWEM and Floquet port simulations show excellent agreement with travelingwave measurements in both guided and free-space scenarios. Furthermore, the discussed broadband methods predict and measure frequency-dependent effects that are not covered by EMTs and resonance measurement setups, highlighting the necessity to adopt more sophisticated simulation tools for the design of graded-index devices. It is shown that the effective media bandwidth of dielectric crystals depends on the respective unit cell symmetry and that FCC symmetry obtains a significantly increased bandwidth compared with SC symmetry.

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“…Metals and plastics (with subsequent metal coating) are the most commonly used materials for 3D printed microwave components. Reference [2] provides a general comparison of different approaches of manufacturing waveguides, including a discussion of metalization.…”

Section: Introductionmentioning

confidence: 99%

Additive Manufacturing of Non-homogenous Dielectric Waveguide Structures and Filters

Robins

Arsanjani

Bartlett

et al. 2021

2021 IEEE MTT-S International Microwave Filter Workshop (IMFW)

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This paper investigates the use of 3D-printed alumina ceramics to achieve variable dielectric constants for novel microwave applications. An introduction to lithography-based ceramic manufacturing exhibits the novel process and material properties, while detailing printing techniques for achieving gradient and equivalent dielectric constants. Printed samples of non-homogeneous dielectrics are presented and briefly discussed. Potential end-use for microwave components are discussed with emphasis on future filter applications.

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A study of additive manufacturing technologies and metallizing techniques for microwave waveguide components

Cited by 6 publications

References 22 publications

Synthesis of Rectangular Waveguide Filters With Smooth Profile Oriented to Direct Metal Additive Manufacturing

Synthesis of Rectangular Waveguide Filters With Smooth Profile Oriented to Direct Metal Additive Manufacturing

Broadband Effective Permittivity Simulation and Measurement Techniques for 3-D-Printed Dielectric Crystals

Additive Manufacturing of Non-homogenous Dielectric Waveguide Structures and Filters

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