Journal
IEEE TRANSACTIONS ON MICROWAVE THEORY AND TECHNIQUES
Volume 67, Issue 3, Pages 883-895Publisher
IEEE-INST ELECTRICAL ELECTRONICS ENGINEERS INC
DOI: 10.1109/TMTT.2018.2889452
Keywords
Digital light processing (DLP); magic tee; matching; metallization; millimeter wave; 3-D printing; W-band; waveguide
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Additive manufacturing technology has enabled the manufacturing of complex structures, especially those with intricate internal features. This paper proposes a method for building complex-structured millimeter-wave waveguides using a strategy that combines digital light processing 3-D printing technology, a curved corner design, an off-axis print angle of 45 degrees, and a robust postmetallization process. To demonstrate the capability of this combined-strategy method, a traditional magic tee prototype and an adapted inherently matched magic tee prototype are fabricated for use in the W-band. The measured performance of the fabricated inherently matched magic tee demonstrates return loss better than 13.5 dB, isolation coefficients higher than 15.7 dB, insertion losses smaller than 1.3 dB, and a magnitude imbalance of less than 1.3 dB across 80-105 GHz. The 3-D printed magic tee has a comparable performance to a W-band CNC-machined magic tee but weighs 77.5% less than the metallic one.
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