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3-D printed metal-pipe rectangular waveguides

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Title: 3-D printed metal-pipe rectangular waveguides
Authors: D'Auria, M
Otter, WJ
Hazell, J
Gillatt, BTW
Long-Collins, C
Ridler, NM
Lucyszyn, S
Item Type: Journal Article
Abstract: This paper first reviews manufacturing technologies for realizing air-filled metal-pipe rectangular waveguides (MPRWGs) and 3-D printing for microwave and millimeter-wave applications. Then, 3-D printed MPRWGs are investigated in detail. Two very different 3-D printing technologies have been considered: low-cost lower-resolution fused deposition modeling for microwave applications and higher-cost high-resolution stereolithography for millimeter-wave applications. Measurements against traceable standards in MPRWGs were performed by the U.K.'s National Physical Laboratory. It was found that the performance of the 3-D printed MPRWGs were comparable with those of standard waveguides. For example, across X-band (8-12 GHz), the dissipative attenuation ranges between 0.2 and 0.6 dB/m, with a worst case return loss of 32 dB; at W-band (75-110 GHz), the dissipative attenuation was 11 dB/m at the band edges, with a worst case return loss of 19 dB. Finally, a high-performance W-band sixth-order inductive iris bandpass filter, having a center frequency of 107.2 GHz and a 6.8-GHz bandwidth, was demonstrated. The measured insertion loss of the complete structure (filter, feed sections, and flanges) was only 0.95 dB at center frequency, giving an unloaded quality factor of 152--clearly demonstrating the potential of this low-cost manufacturing technology, offering the advantages of lightweight rapid prototyping/manufacturing and relatively very low cost when compared with traditional (micro)machining.
Issue Date: 18-Sep-2015
Date of Acceptance: 22-Jul-2015
URI: http://hdl.handle.net/10044/1/25936
DOI: 10.1109/TCPMT.2015.2462130
ISSN: 2156-3985
Publisher: Institute of Electrical and Electronics Engineers
Start Page: 1339
End Page: 1349
Journal / Book Title: IEEE Transactions on Components, Packaging, and Manufacturing Technology
Volume: 5
Issue: 9
Copyright Statement: © 2015 IEEE. Translations and content mining are permitted for academic research only. This is an Open Access article, with further information at https://dx.doi.org/10.1109/TCPMT.2015.2462130
Sponsor/Funder: Engineering & Physical Science Research Council (E
Funder's Grant Number: PO 500064496 (IeMRC)
Keywords: 3-D Printing
Additive Manufacturing
Science & Technology
Engineering, Manufacturing
Engineering, Electrical & Electronic
Materials Science, Multidisciplinary
Materials Science
3-D printing
additive manufacturing
fused deposition modeling (FDM)
metal-pipe rectangular waveguide (MPRWG)
rapid manufacturing
rectangular waveguide
stereolithography apparatus (SLA)
Publication Status: Published
Online Publication Date: 2015-08-20
Appears in Collections:Electrical and Electronic Engineering
Faculty of Engineering