Metallization Processes for 3D Printed Rectangular Waveguides in E- and D-Band

Different metallization techniques for 3D printed plastic rectangular waveguides are evaluated in E- and D-band for split block and monolithic waveguides from different base materials. The metallization techniques include physical vapor deposition, electroplating and electroless plating. The measured attenuation of the 3D printed waveguides is highly comparable to commercially fabricated metal waveguides. For split block waveguides, electroplating as a final plating step showed the lowest attenuation. For monolithic waveguides, electroless copper plating showed very good results. Further, the metallization techniques are analyzed regarding different aspects such as repeatability, resin dependence and cost.