Towards E-band Wavelength: 3D Printed Gaussian Corrugated Horn for Cassegrain Antenna Application

Two Gaussian profile conical horn antennas for use within the E-band spectrum are presented. The proposed conical horn antenna is designed in three segments: Mode converter, phasing and profiled sections. These two horns with Cos n-like radiation patterns as Cassegrain antenna illuminators are analyzed to have high efficiency over the E-band (60-100GHz). Simulations show reasonable results, therefore allowing for reliable predictability. A couple of printing technologies and metal materials to realize proposed designs are analyzed with material characterizations throughout simulations, namely selective laser melting (SLM) using Cu-15Sn material and binder sintering on 316L stainless with
$2.79 \mu \mathrm{m}, 12.79 \mu \mathrm{m}$
surface roughness, respectively. The slot-to-ridge width ratio for both designs is fixed to 4: 1 ratio, with a pitch of
$\lambda/4$
at 100 GHz. The provided horn antennas' impedance bandwidth (|S11| < −24 dB) covers the whole intended operational band for both E- and D spectrum. The realized in-band gain for the E-band antennas is higher than 22.14 and 22, respectively.