3D Printing of Complex, High-Performance Millimeter-Wave Components

We report on a complete fabrication process to realize complex, high-performance microwave components using digital-light-processing (DLP) 3D printing. Our approach addresses numerous challenges of successful component realization, including: metalization of acrylate-based polymers, defect reduction in printing, increased precision through off-axis printing of waveguide channels and re-design of precision internal structures for self-supporting in the build process. The results of our approach have produced complex microwave components with performance comparable to commercial, multi-part CNC machined components.