Polymer-Based 3-D Printed 140 to 220 GHz Metal Waveguide Thru Lines, Twist and Filters
This paper demonstrates the current state-of-the-art in low-cost, low loss ruggedized polymer-based 3-D printed G-band (140 to 220 GHz) metal-pipe rectangular waveguide (MPRWG) components. From a unique and exhaustive up-to-date literature review, the main limitations for G-band split-block MPRWGs a...
| Main Authors: | , , , , , |
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| Format: | Article |
| Language: | English |
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IEEE
2023-01-01
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| Series: | IEEE Access |
| Subjects: | |
| Online Access: | https://ieeexplore.ieee.org/document/10078872/ |
| _version_ | 1797851510538764288 |
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| author | Roshan Payapulli Liyan Zhu Sang-Hee Shin Manoj Stanley Nick M. Ridler Stepan Lucyszyn |
| author_facet | Roshan Payapulli Liyan Zhu Sang-Hee Shin Manoj Stanley Nick M. Ridler Stepan Lucyszyn |
| author_sort | Roshan Payapulli |
| collection | DOAJ |
| description | This paper demonstrates the current state-of-the-art in low-cost, low loss ruggedized polymer-based 3-D printed G-band (140 to 220 GHz) metal-pipe rectangular waveguide (MPRWG) components. From a unique and exhaustive up-to-date literature review, the main limitations for G-band split-block MPRWGs are identified as electromagnetic (EM) radiation leakage, assembly part alignment and manufacturing accuracy. To mitigate against leakage and misalignment, we investigate a ‘trough-and-lid’ split-block solution. This approach is successfully employed in proof-of-concept thru lines, and in the first polymer-based 3-D printed 90° twist and symmetrical diaphragm inductive iris-coupled bandpass filters (BPFs) operating above 110 GHz. An inexpensive desktop masked stereolithography apparatus 3-D printer and a commercial copper electroplating service are used. Surface roughness losses are calculated and applied to EM (re-)simulations, using two modifications of the Hemispherical model. The 7.4 mm thru line exhibits a measured average dissipative attenuation of only 12.7 dB/m, with rectangular-to-trapezoidal cross-sectional distortion being the main contributor to loss. The 90° twist exhibits commensurate measured performance to its commercial counterpart, despite the much lower manufacturing costs. A detailed time-domain reflectometry analysis of flange quality for the thru lines and 90° twists has also been included. Finally, a new systematic iris corner rounding compensation technique, to correct passband frequency down-shifting is applied to two BPFs. Here, the 175 GHz exemplar exhibits only 0.5% center frequency up-shifting. The trough-and-lid assembly is now a viable solution for new upper-mm-wave MPRWG components. With this technology becoming less expensive and more accurate, higher frequencies and/or more demanding specifications can be implemented. |
| first_indexed | 2024-04-09T19:17:55Z |
| format | Article |
| id | doaj.art-728d98cc0e1a4d3c9b46f450ab4ee6b0 |
| institution | Directory Open Access Journal |
| issn | 2169-3536 |
| language | English |
| last_indexed | 2024-04-09T19:17:55Z |
| publishDate | 2023-01-01 |
| publisher | IEEE |
| record_format | Article |
| series | IEEE Access |
| spelling | doaj.art-728d98cc0e1a4d3c9b46f450ab4ee6b02023-04-05T23:00:29ZengIEEEIEEE Access2169-35362023-01-0111322723229510.1109/ACCESS.2023.326124110078872Polymer-Based 3-D Printed 140 to 220 GHz Metal Waveguide Thru Lines, Twist and FiltersRoshan Payapulli0Liyan Zhu1https://orcid.org/0000-0003-4717-7906Sang-Hee Shin2https://orcid.org/0000-0001-8849-4241Manoj Stanley3https://orcid.org/0000-0003-2276-9323Nick M. Ridler4https://orcid.org/0000-0002-1462-2914Stepan Lucyszyn5https://orcid.org/0000-0003-4878-3801Department of Electrical and Electronic Engineering, Imperial College London, London, U.KDepartment of Electrical and Electronic Engineering, Imperial College London, London, U.KDepartment of Electrical and Electronic Engineering, Imperial College London, London, U.KDepartment of Electromagnetic and Electrochemical Technologies, National Physical Laboratory, Teddington, U.KDepartment of Electromagnetic and Electrochemical Technologies, National Physical Laboratory, Teddington, U.KDepartment of Electrical and Electronic Engineering, Imperial College London, London, U.KThis paper demonstrates the current state-of-the-art in low-cost, low loss ruggedized polymer-based 3-D printed G-band (140 to 220 GHz) metal-pipe rectangular waveguide (MPRWG) components. From a unique and exhaustive up-to-date literature review, the main limitations for G-band split-block MPRWGs are identified as electromagnetic (EM) radiation leakage, assembly part alignment and manufacturing accuracy. To mitigate against leakage and misalignment, we investigate a ‘trough-and-lid’ split-block solution. This approach is successfully employed in proof-of-concept thru lines, and in the first polymer-based 3-D printed 90° twist and symmetrical diaphragm inductive iris-coupled bandpass filters (BPFs) operating above 110 GHz. An inexpensive desktop masked stereolithography apparatus 3-D printer and a commercial copper electroplating service are used. Surface roughness losses are calculated and applied to EM (re-)simulations, using two modifications of the Hemispherical model. The 7.4 mm thru line exhibits a measured average dissipative attenuation of only 12.7 dB/m, with rectangular-to-trapezoidal cross-sectional distortion being the main contributor to loss. The 90° twist exhibits commensurate measured performance to its commercial counterpart, despite the much lower manufacturing costs. A detailed time-domain reflectometry analysis of flange quality for the thru lines and 90° twists has also been included. Finally, a new systematic iris corner rounding compensation technique, to correct passband frequency down-shifting is applied to two BPFs. Here, the 175 GHz exemplar exhibits only 0.5% center frequency up-shifting. The trough-and-lid assembly is now a viable solution for new upper-mm-wave MPRWG components. With this technology becoming less expensive and more accurate, higher frequencies and/or more demanding specifications can be implemented.https://ieeexplore.ieee.org/document/10078872/Additive manufacturing3-D printingmillimeter-waveG-bandWR-5rectangular waveguide |
| spellingShingle | Roshan Payapulli Liyan Zhu Sang-Hee Shin Manoj Stanley Nick M. Ridler Stepan Lucyszyn Polymer-Based 3-D Printed 140 to 220 GHz Metal Waveguide Thru Lines, Twist and Filters IEEE Access Additive manufacturing 3-D printing millimeter-wave G-band WR-5 rectangular waveguide |
| title | Polymer-Based 3-D Printed 140 to 220 GHz Metal Waveguide Thru Lines, Twist and Filters |
| title_full | Polymer-Based 3-D Printed 140 to 220 GHz Metal Waveguide Thru Lines, Twist and Filters |
| title_fullStr | Polymer-Based 3-D Printed 140 to 220 GHz Metal Waveguide Thru Lines, Twist and Filters |
| title_full_unstemmed | Polymer-Based 3-D Printed 140 to 220 GHz Metal Waveguide Thru Lines, Twist and Filters |
| title_short | Polymer-Based 3-D Printed 140 to 220 GHz Metal Waveguide Thru Lines, Twist and Filters |
| title_sort | polymer based 3 d printed 140 to 220 ghz metal waveguide thru lines twist and filters |
| topic | Additive manufacturing 3-D printing millimeter-wave G-band WR-5 rectangular waveguide |
| url | https://ieeexplore.ieee.org/document/10078872/ |
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