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Metal-Only Additive Manufacturing of V -Band Lightweight Waveguide and Horn Components
KTH, School of Electrical Engineering and Computer Science (EECS), Electrical Engineering, Electromagnetic Engineering and Fusion Science.ORCID iD: 0000-0003-0688-8648
Northern Waves AB, Stockholm, Sweden, 115 43.
Universidad de Sevilla, Department of Applied Physics1, ETS Ingeniería Informática, Seville, Spain.
KTH, School of Electrical Engineering and Computer Science (EECS), Electrical Engineering, Electromagnetic Engineering and Fusion Science.ORCID iD: 0000-0002-4900-4788
2025 (English)In: IEEE transactions on microwave theory and techniques, ISSN 0018-9480, E-ISSN 1557-9670, Vol. 73, no 9, p. 5675-5685Article in journal (Refereed) Published
Abstract [en]

Additive manufacturing (AM) is growing as a key technology for the miniaturization and integration of microwave components. Among several AM processes, laser powder-bed fusion (LPBF) is especially convenient for waveguides and horns because it allows for 3-D printing of metal-only parts with high accuracy and low surface roughness. During the 3-D printing process, metallic powder materials are selectively consolidated by melting layer by layer together using a heat source, that is, a laser, allowing for adaptation to complex and shaped structures. The present study investigates the feasibility of using LPBF-AM to fabricate waveguides and geodesic $H$ -plane horns in $V$ -band. Geodesic $H$ -plane horns comprise two parallel curved metallic plates to reduce phase errors and achieve high gain and aperture efficiency, and are particularly suited to be fabricated using LPBF. The monolithic waveguides demonstrate significantly better performance than their two-piece counterparts, achieving an average attenuation coefficient of 5.3 dB/m for the straight waveguide and 8 dB/m for the 90 $^\circ$ $E$ -plane waveguide bend at 50-70 GHz. Similarly, the monolithic geodesic $H$ -plane horn has higher realized gains and radiation efficiencies with only a sixth of the weight compared to the two-piece version at 52-68 GHz. The results demonstrate that the LPBF-AM technique is a promising candidate to produce monolithic metal-only microwave components in $V$ -band.

Place, publisher, year, edition, pages
Institute of Electrical and Electronics Engineers (IEEE) , 2025. Vol. 73, no 9, p. 5675-5685
Keywords [en]
3-D printing, additive manufacturing (AM), geodesic H -plane horns, laser powder-bed fusion (LPBF), metal-only, V -band, waveguides
National Category
Other Electrical Engineering, Electronic Engineering, Information Engineering
Identifiers
URN: urn:nbn:se:kth:diva-367286DOI: 10.1109/TMTT.2024.3451065ISI: 001317706000001Scopus ID: 2-s2.0-85204949536OAI: oai:DiVA.org:kth-367286DiVA, id: diva2:1984672
Note

QC 20260306

Available from: 2025-07-17 Created: 2025-07-17 Last updated: 2026-03-06Bibliographically approved
In thesis
1. Ray Tracing and Physical Optics for Geodesic and GRIN Lens Antennas
Open this publication in new window or tab >>Ray Tracing and Physical Optics for Geodesic and GRIN Lens Antennas
2025 (English)Doctoral thesis, comprehensive summary (Other academic)
Abstract [en]

This thesis investigates the ray tracing (RT) and physical optics (PO) method for geodesic and gradient-index (GRIN) lens antennas in both far and near fields at millimeter-wave frequencies (from around 30 GHz up to 110 GHz). In particular, parallel-plate-waveguide (PPW) based GRIN lenses and geodesic H-plane horns are studied to realize high-gain antennas in the far-field region. In addition, radial GRIN lenses are investigated to produce quasi-nondiffracting beams in the near-field region. Ray techniques are used in all cases.

First, a highly time-efficient and reasonably accurate RT-PO model is proposed as a fast design tool. The model can be divided into three steps:(i) calculation of ray trajectories and the corresponding phase distribution applying geometric optics, (ii) evaluation of the amplitude distribution using ray-tube power conservation theory, and (iii) calculation of radiation far fields applying the field equivalence principle in PO. In this thesis, important antenna parameters are obtained from the model, including the radiation pattern, directivity, dielectric loss, and gain. Two PPW-based GRIN lenses, the Mikaelian and Luneburg lenses with H-plane beam steering capabilities, are studied to validate the proposed RT-PO model.

The RT-PO model is also used to design novel geodesic H-plane horn antennas. An appropriate geodesic shape is proposed and optimized using the fast RT-PO tool to correct for phase errors in regular H-plane horns.The resulting fully metallic antennas maintain a stable fan-shaped beam in a large bandwidth with high gain, high aperture efficiency, and high radiation efficiency. Furthermore, a metal-only additive manufacturing (AM) technique is used to monolithically manufacture them in a compact and lightweight manner. Successful prototyping has been shown up to the W-band.

In addition to far-field applications, this thesis also investigates radial GRIN lenses for near-field beamforming. A quasi-closed-form radial GRIN profile is derived based on optical path lengths of the traced rays to generate quasi-nondiffracting beams. The proposed profile can be applied for a wide range of lens parameters and operating frequencies. Quasi-periodic structures arranged in a highly symmetric lattice are used to experimentally realize this lens using a dielectric AM technique to cover the entire Ka-band. The proposed profile is also equally applicable for higher frequencies.

Abstract [sv]

Denna avhandling undersöker strålspårning (RT) och fysikalisk optik (PO) för geodetiska och gradientindex- (GRIN) linsantenner i både fjärr- och närfält vid millimetervägsfrekvenser (från cirka 30 GHz upp till 110 GHz). I synnerhet studeras parallella plattvågledar- (PPW) baserade GRIN-linser och geodetiska H-planshorn för att generera högförstärkande antenner i fjärrfältet. Dessutom undersöks radiella GRIN-linser för att producera kvasi-icke-diffrakteran-de balkar i närfältet. Stråltekniker används i samtliga fall.

Den mycket tidseffektiva och rimligt noggranna RT-PO-modellen föreslås först som ett snabbt designverktyg. Modellen kan delas in i tre steg: (i) beräk-ning av strålbanor och motsvarande fasfördelning med hjälp av geometrisk optik, (ii) utvärdering av amplitudfördelningen med hjälp av strålrör effektbevarandeteori, och (iii) beräkning av strålningsfjärrfält med hjälp av fält-ekvivalensprincipen i PO. I denna avhandling erhålls viktiga antennparametrar från modellen, inklusive strålningmönster, riktningsförmåga, dielektrisk förlust och förstärkning. Två PPW-baserade GRIN-linser, Mikaelian- och Luneburg-linserna med H-plan strålstyrningfunktioner, studeras för att validera den föreslagna RT-PO-modellen.

RT-PO-modellen används också för att designa nya geodetiska H-plan-hornantenner. En lämplig geodetisk form föreslås och optimeras med hjälp av det snabba RT-PO-verktyget för att korrigera för fasfel i vanliga H-planhorn. De resulterande helt metalliska antennerna bibehåller en stabil solfjäderform-ad stråle över ett brett frekvensband, med hög förstärkning, hög bländare-ffektivitet och hög strålningsverkningsgrad. Dessutom används en additiv tillverkningsteknik (AM) med enbart metall för att monolitiskt tillverka dem på ett kompakt och lätt sätt. Framgångsrik prototypframställning har demonstrerats upp till W-bandet.

Förutom tillämpningar i fjärrfältet undersöker denna avhandling även radiella GRIN-linser för närfältsstrålformning. En kvasi-sluten radiell GRIN-profil härleds baserat på optiska väglängder för de spårade strålarna för att generera kvasi-icke-diffrakterande strålar. Den föreslagna profilen kan tillämpas för ett brett spektrum av linsparametrar och driftsfrekvenser. Kvasiperiodiska strukturer arrangerade i ett mycket symmetriskt gitter används för att experimentellt realisera denna lins med hjälp av dielektrisk AM som täcker hela Ka-bandet. Den föreslagna profilen är även lika tillämplig för högre frekvenser.

Place, publisher, year, edition, pages
KTH Royal Institute of Technology, 2025. p. 81
Series
TRITA-EECS-AVL ; 2025:70
Keywords
Additive manufacturing (AM), antenna, geodesic H-plane horn, gradient-index (GRIN) lens, parallel plate waveguide (PPW), physical optics (PO), ray tracing (RT), Additiv tillverkning (AM), antenn, geodetisk H-planshorn, gradientindexlins (GRIN), parallellplattad vågledare (PPW), fysisk optik (PO), strålspårning (RT)
National Category
Telecommunications
Identifiers
urn:nbn:se:kth:diva-369099 (URN)978-91-8106-325-7 (ISBN)
Public defence
2025-09-29, https://kth-se.zoom.us/j/67589198814, Room nr. 132, F3, Lindstedtsvägen 26 & 28, Stockholm, 13:00 (English)
Opponent
Supervisors
Note

QC 20250828

Available from: 2025-08-28 Created: 2025-08-27 Last updated: 2025-09-15Bibliographically approved

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Chen, MingzhengQuevedo-Teruel, Oscar

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