Microfabricated plastic 95-GHz rectangular waveguide

A plastic, 95-GHz rectangular waveguide with an integrated plastic flange has been successfully demonstrated using micro hot embossing and electroplating technologies. The prototype device shows s/sub 11/ and s/sub 21/ values of -20.7 dB and -1.35 dB at 95GHz, respectively, and the signal transmission rate is 73.3% as compared to commercial all-metal waveguides at 85%. The time domain measurement showed the system losses are mainly due to the discontinuity losses at the interfaces between the network analyzer adaptors and the waveguide input/output ports and could be further minimized in future integrated systems. As such, this new class of plastic waveguides has potential applications in replacing the expensive yet bulky/heavy metallic waveguides in current millimeter-wave systems.