Evaluating Performance of 3D-Printed Metallic Rectangular mm-Wave and THz Waveguides

Rectangular Waveguides are standard RF interconnects, but are increasingly difficult to manufacture and align at higher frequencies. 3D printing, which is constantly improving, allows for intricate shapes and compact designs, thus offering potential for future high-frequency waveguides. This abstract evaluates the performance of metallic 3D printed rectangular waveguides made of steel at various frequency bands up to 0.5 THz. Waveguides are measured for insertion loss and the results are discussed, highlighting the performance enhancement due to gold plating.

I. Introduction

Rectangular WR waveguides are known for their minimal-loss operation and are the conventional choice for various applications below 1 THz. These waveguides are typically made of gold-plated copper or aluminium alloys and are manufactured using CNC (Computer Numerical Control) machining, which is highly precise but involves significant tooling and labour costs.