Experimental research activity on additive manufacturing of microwave passive waveguide components

All metal passive waveguide components are key building-blocks of several RF systems used for telecommunications, navigation, imaging, radio-astronomy, and cosmology. The accurate manufacture of these devices in Additive Manufacturing (AM) technologies can open the way to a high integration level of microwave functionalities with a significant cost and mass reduction. In the paper, after an introduction on the most common AM technologies with particular detail on selective laser melting (SLM) and stereo-lithography apparatus (SLA) processes, the results on the on-going research activity are discussed. Measured performances are reported for AM prototypes of Ku/K/Ka-band rectangular and circular waveguide lines, microwave filters and a smooth wall horn.