Effect of Build Orientation and Laser Power on Microwave Loss in Metal Additive Manufactured Components

The adoption of metal additive manufacturing into the production of passive microwave components is still in its relative infancy. However, it is of increasing interest due to the offer of geometrical design freedom and significant weight reduction. The electrical properties of additive manufactured components are still inferior to traditional manufacturing techniques owing to the poor surface finish, especially on overhanging surfaces, which are unavoidable in three-dimensional microwave components. In this paper we present experimental findings on the disparity in microwave surface resistance values between three common build orientations, as well as findings that establish a connection between increasing downskin laser power and a reduction in surface resistance for overhanging surfaces. Finally, additive manufactured rectangular waveguide sections are measured to assess the influence of combined upward and downward facing surfaces on surface resistance.

Automated summary

This paper explores the adoption of metal additive manufacturing in the production of passive microwave components, highlighting its advantages in geometrical design freedom and weight reduction, while also addressing some challenges in terms of microwave surface resistance values.