Groove Gap Waveguide in 3-D Printed Technology for Low Loss, Weight, and Cost Distribution Networks

Abstract

This paper presents the design and fabrication of low loss, weight, and cost prototypes in groove gap waveguide technology at Ka-band, manufactured with a metallized 3-D printing technique. A wide analysis of loss mechanisms and printing imperfections has been conducted, as well as the effect of temperature on structural deformations. Metallized 3-D printed and CNC machined prototypes have been compared and characterized with simulations and measurements at a band from 28 to 30 GHz. The average measured losses for metallized plastic prototypes are 1.4 dB/m.

Performance Assessment of Gap-Waveguide Array Antennas: CNC Milling Versus Three-Dimensional Printing

“…One might state, therefore, that the overall fabrication quality of the aluminum antenna is notably better than that observed for the 3D-printed prototype. This fact contradicts to a certain extent what it is affirmed in [3], where larger roughness was observed in the aluminum version. It must be pointed out that the aluminum breadboard in [3] was subject to a sanding process, which is undoubtedly responsible for such roughness.…”

“…This fact contradicts to a certain extent what it is affirmed in [3], where larger roughness was observed in the aluminum version. It must be pointed out that the aluminum breadboard in [3] was subject to a sanding process, which is undoubtedly responsible for such roughness. As it is already suggested in [3], an eventual finishing process for aluminum pieces may lead to additional roughness which significantly increases the conductor losses.…”

“…A critic comparison of the experimental results and their connection to fabrication techniques are discussed next. The conclusions drawn in [3] will be taken as a reference, given the common points with this work.…”

“…Interestingly, scarce publications on GW technology designs using additive manufacturing (AM) can be found in the literature. Nevertheless, a very complete study comparing milling and 3D printing in terms of waveguide losses in transitions, power dividers or bends was recently released [3]. But the overall performance of a GW antenna was not covered there.…”

A New 4 × 4 Rectangular Waveguide Short-Slot Coupler in 3D Printed Technology at Ku-Band

“…Additive manufacturing [16,17] using plastic was used for the prototype implementation. Since the 3D printed waveguide components were manufactured from plastic, they must be metalized using either copper [16,17] or silver [18]. A 3D printer was used with Polylactic Acid (PLA biopolymer) material.…”