Additive manufacturing of Ka-band dual-polarization waveguide components

Additive manufacturing (AM) is emerging as a key technology for the minimization and integration of microwave antenna systems. Among the several AM processes, selective laser melting (SLM) is rather convenient for waveguide components, since it allows for all-metal parts with a mechanical accuracy within 30-60 μm and an equivalent surface electrical resistivity in the range of 10-20 μΩcm. This paper reports on the assessment of the SLM applicability to the manufacturing of dual-polarization waveguide components operating in Ka-band, namely, a septum polarizer, a smooth-wall feed horn integrated with the septum polarizer, and an orthomode transducer (OMT). In order to achieve high electromagnetic performance in the Ka-band, the architectures have been optimized for the manufacturing process, above all in terms of orientation on the building platform and minimization of supporting structures. As a consequence, the corresponding prototypes exhibit measured performances in significant agreement with the predicted values. As an example, the return loss of all the components has been measured to be as high as 25 dB, while the measured isolation between the rectangular waveguide ports of the OMT is better than 47 dB.