Polymer-based 3-D printing of G-band metal-pipe rectangular waveguide components

Abstract

The objective of this thesis is to investigate the use of low-cost polymer-based 3-D printing for G-band (140 to 220 GHz) metal-pipe rectangular waveguide (MPRWG) components. First, various preliminary designs are investigated. Then, a successful ‘trough-and-lid’ assembly is demonstrated, which mitigates against the main design challenges for split-block waveguide construction at upper-millimeter-wave frequencies (ca. 100 GHz to 300 GHz), and can be realized using low-cost 3-D printing and conventional metal plating techniques. With this assembly, inexpensive masked stereolithographic apparatus (MSLA) 3-D printers and a standard commercial copper electroplating service are used. The trough-and-lid assembly is expected to provide a standard solution for the low-cost and low loss realization of most MPRWG implementations above 100 GHz; previously, this was infeasible without the use of high-cost, state-of-the-art 3-D printing and/or custom-developed metal plating techniques. Three different component types are successfully demonstrated: (i) straight thru lines; (ii) 90° twists; and (iii) bandpass filters (BPFs). Along with frequency-domain S-parameter measurements, a detailed time-domain reflectometry analysis is also included. For the more accurate characterization of these components, the additional insertion loss due to conductor surface roughness is investigated. Finally, the integration of an MPRWG component into a millimeter-wave subsystem, which is based on the design of a radiometer front-end, is presented.