Integration of RF functionalities in microwave waveguide components through 3D metal printing

This work reports on the integration of RF functionalities in microwave waveguide components through the selective laser melting process. A specific integrated component has been developed for the relevant application domain of satellite communications. The component operates in the Ku-K bands and integrates a H-plane bend, a 90-deg twist and ninth-order pass-band filter. The AlSi10Mg prototype manufactured through selective laser melting exhibits excellent RF performances (return loss > 20 dB, insertion loss < 0.23 dB, and rejection > 60 dB), while significantly minimizing mass, envelope and mechanical complexity.