D-band Waveguide Diplexer Fabricated Using Micro Laser Sintering

Yu，Yang1; Wang，Yi2; Skaik，Talal2; Starke，Thomas3; Shang，Xiaobang4; Lancaster，Michael J.2; Hunyor，Peter5; Huggard，Peter5; Wang，Hui5; Harris，Michael5; Beardsley，Mat5; Cheng，Qingsha S.6

2022

10.1109/TCPMT.2022.3204887

IEEE Transactions on Components Packaging and Manufacturing Technology   Impact Factor & Quartile

2156-3950

2156-3985

We report a D-band waveguide diplexer, with two passbands of 130 - 134 GHz and 151.5 - 155.5 GHz, fabricated using micro laser sintering (MLS) additive manufacturing with stainless-steel. This is the first demonstration of metal 3D printing technology for multi-port filtering device at a sub-THz frequency. For comparison, the same diplexer design has also been implemented using computer numerical controlled (CNC) milling. The diplexer, designed using coupling matrix theory, employs an all-resonator and E-plane split-block structure. The two channels are folded for compactness. A staircase coupled structure is used in one channel to increase the isolation performance. The printed waveguide flanges are modified to adapt to the limited printing volume from the MLS. Effects of fabrication tolerance on the diplexer are investigated. An effective and unconventional electroless plating process is developed. The measured average insertion losses of the gold coated diplexer are 1.31 dB and 1.37 dB respectively. Respective frequency shifts from design values are 0.92% and 1.1%, and bandwidth variations are 4% and 15%. From a comprehensive treatment of the end-to-end manufacture process, the work demonstrates MLS to be a promising fabrication technique for complex waveguide devices at sub-THz frequency range.

Additive manufacturing all-resonator structure Bandwidth CNC machining Couplings Laser sintering micro laser sintering Passband surface treatment Three-dimensional printing Transmission line matrix methods waveguide diplexer Waveguide lasers

SCI ; EI

English

Others

U.K. Engineering and Physical Science Research Council["EP/S013113/1","EP/P020615/1"] ; National Natural Science Foundation of China[62071211] ; University Key Research Project of Guangdong Province[2018KZDXM063]

Engineering ; Materials Science

Engineering, Manufacturing ; Engineering, Electrical & Electronic ; Materials Science, Multidisciplinary

WOS:000866498100008

IEEE-INST ELECTRICAL ELECTRONICS ENGINEERS INC

20223812755340

3D printers ; Bandpass filters ; Electroless plating ; Fabrication ; Laser heating ; Matrix algebra ; Resonators ; Sintering ; Structure (composition) ; Surface treatment ; Waveguide filters

Electroless Plating:539.3.2 ; Electric Filters:703.2 ; Waveguides:714.3 ; Information Theory and Signal Processing:716.1 ; Laser Applications:744.9 ; Printing Equipment:745.1.1 ; Algebra:921.1 ; Materials Science:951

2-s2.0-85137904128

Scopus

1.National Space Science Center, Key Laboratory of Microwave Remote Sensing, Chinese Academy of Sciences, Beijing, China
2.School of Electrical, Electronic and Systems Engineering, University of Birmingham, Birmingham, U.K
3.3D MicroPrint GmbH Technologie, Chemnitz, DE, Germany
4.National Physical Laboratory, Teddington, UK
5.STFC Rutherford Appleton Laboratory, UK
6.Department of Electrical and Electronic Engineering, Southern University of Science and Technology, Shenzhen, P.R. China

Yu，Yang,Wang，Yi,Skaik，Talal,et al. D-band Waveguide Diplexer Fabricated Using Micro Laser Sintering[J]. IEEE Transactions on Components Packaging and Manufacturing Technology,2022,12(9):1446-1457.

Yu，Yang.,Wang，Yi.,Skaik，Talal.,Starke，Thomas.,Shang，Xiaobang.,...&Cheng，Qingsha S..(2022).D-band Waveguide Diplexer Fabricated Using Micro Laser Sintering.IEEE Transactions on Components Packaging and Manufacturing Technology,12(9),1446-1457.

Yu，Yang,et al."D-band Waveguide Diplexer Fabricated Using Micro Laser Sintering".IEEE Transactions on Components Packaging and Manufacturing Technology 12.9(2022):1446-1457.