3D Printed Microwave Components for Frequencies above 100 GHz

In this work, 3D printing technology is investigated as a potential manufacturing technique for waveguide components for frequencies above 100 GHz. Two components fabricated by micro laser sintering (MLS) process are outlined and discussed here: a D-band (110-170 GHz) diplexer and H-band (220-330 GHz) filter. Both devices are comprised of rectangular waveguide cavities and made of two split blocks of stainless-steel. The results are promising and they demonstrate that good dimensional accuracy has been achieved by the MLS printer. However, both devices exhibited high insertion losses, a minimum of 4.7 dB for the filter and 4.2 dB for the diplexer. Surface polishing and plating is required to reduce the high losses.