Design and Fabrication of a Full W-Band Multi-Step Waveguide 90° Twist

A compact four-step 90-degree waveguide twist is designed for operation over the full W-band. The waveguide cross section is modified from the conventional sharp-corners rectangle to comply with the fabrication constraints. The designed twist is fabricated by two processes; CNC machining of the four steps then assembling, and 3D printing through direct metal laser sintering (DMLS). Both of the realized twists measure better performance than that of the commercially-available longer and more expensive twists. Moreover, they are better suited for integrated systems and delicate machining restrictions in W band.