Additive manufacturing of Ku/K-band waveguide filters: a comparative analysis among selective-laser melting and stereolithography

This study describes an experimental research activity on the manufacturing of passive waveguide components by means of two additive technologies, namely the selective-laser melting and the stereo-lithography processes. The former is a power-bed fusion process, for which aluminium, titanium, and steel powders have been considered in this study. The latter is based on the photopolymerisation of a resin vat. This technology has been applied in conjunction with an acrylonitrile-butadiene-styrene-like polymer and a subsequent electrolytic copper plating for the metallisation of the internal channels. Wideband filters operating in Ku/K band have been developed as benchmarks, for which detailed comparisons between simulations and measurements are reported.