CNC-Machined and 3D-Printed Metal G-band Diplexers for Earth Observation Applications

Talal Skaik; Peter Hunyor; Mat Beardsley; Hui Wang; Peter G. Huggard; Yi Wang

doi:10.1109/TCPMT.2024.3392999

CNC-Machined and 3D-Printed Metal G-band Diplexers for Earth Observation Applications

Talal Skaik^*, Peter Hunyor, Mat Beardsley, Hui Wang, Peter G. Huggard, Yi Wang

^*Corresponding author for this work

Electronic, Electrical and Systems Engineering

Research output: Contribution to journal › Article › peer-review

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Abstract

This work presents two manufacturing approaches for waveguide diplexers applicable to separating two of the G-band, 140-220 GHz, channels used in space borne radiometry of the Earth’s atmosphere. Waveguide diplexing is a lower volume alternative to a quasi-optical, i.e., frequency selective surface based, system. The two channels considered are 164-167 GHz and 175-191 GHz. The diplexer comprises a Y junction with two waveguide-cavity filters. Two high-precision fabrication technologies have been utilized: computer numerical control (CNC) machining and 3D printing. Two units were CNC machined as brass split-blocks and a third was 3D printed monolithically in stainless steel by a micro laser sintering process. The latter is an innovative structure that incorporates the diplexer with the waveguide flanges. All devices were gold coated to reduce loss. Measured insertion losses in the two channels were 0.6 and 0.34 dB for the CNC-machined diplexers and 1.8 and 0.8 dB for the 3D printed diplexer. The maximum frequency shifts from design were 0.695 GHz in the CNC-diplexers and 1.55 GHz in the 3D printed diplexer.

Original language	English
Number of pages	7
Journal	IEEE Transactions on Components, Packaging and Manufacturing Technology
DOIs	https://doi.org/10.1109/TCPMT.2024.3392999
Publication status	Published - 24 Apr 2024

Bibliographical note

Publisher Copyright: IEEE

Keywords

3D printing
CNC machining
Computer numerical control
diplexer
Filters
Flanges
G-band
Gold
Loss measurement
micro laser sintering (MLS)
Microwave Sounder (MWS)
Three-dimensional displays
waveguide filter
Waveguide lasers

ASJC Scopus subject areas

Electronic, Optical and Magnetic Materials
Industrial and Manufacturing Engineering
Electrical and Electronic Engineering

Access to Document

10.1109/TCPMT.2024.3392999Licence: None: All rights reserved

SkaikT2024CNC-Machined_AAM
This is the accepted author manuscript of an article published in IEEE Transactions on Components, Packaging, and Manufacturing Technology; final published version is available at https://doi.org/10.1109/TCPMT.2024.3392999 © 2024 IEEE. Personal use of this material is permitted. Permission from IEEE must be obtained for all other uses, in any current or future media, including reprinting/republishing this material for advertising or promotional purposes, creating new collective works, for resale or redistribution to servers or lists, or reuse of any copyrighted component of this work in other works.
Accepted author manuscript, 1.1 MBLicence: Other (please specify with Rights Statement)

Towards a 3D Printed Terahertz Circuit Technology
Wang, Y. (Co-Investigator) & Lancaster, M. (Principal Investigator)
Engineering & Physical Science Research Council
1/07/19 → 30/04/23
Project: Research Councils
10 MHz to 1.1 THz Vector Network Analyser
Constantinou, C. (Co-Investigator), Lancaster, M. (Co-Investigator), Gashinova, M. (Co-Investigator), Gardner, P. (Researcher), Wang, Y. (Principal Investigator) & Hanham, S. (Co-Investigator)
Engineering & Physical Science Research Council
1/09/17 → 31/08/23
Project: Research Councils

Cite this

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abstract = "This work presents two manufacturing approaches for waveguide diplexers applicable to separating two of the G-band, 140-220 GHz, channels used in space borne radiometry of the Earth{\textquoteright}s atmosphere. Waveguide diplexing is a lower volume alternative to a quasi-optical, i.e., frequency selective surface based, system. The two channels considered are 164-167 GHz and 175-191 GHz. The diplexer comprises a Y junction with two waveguide-cavity filters. Two high-precision fabrication technologies have been utilized: computer numerical control (CNC) machining and 3D printing. Two units were CNC machined as brass split-blocks and a third was 3D printed monolithically in stainless steel by a micro laser sintering process. The latter is an innovative structure that incorporates the diplexer with the waveguide flanges. All devices were gold coated to reduce loss. Measured insertion losses in the two channels were 0.6 and 0.34 dB for the CNC-machined diplexers and 1.8 and 0.8 dB for the 3D printed diplexer. The maximum frequency shifts from design were 0.695 GHz in the CNC-diplexers and 1.55 GHz in the 3D printed diplexer.",

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journal = "IEEE Transactions on Components, Packaging and Manufacturing Technology",

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AU - Wang, Yi

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AB - This work presents two manufacturing approaches for waveguide diplexers applicable to separating two of the G-band, 140-220 GHz, channels used in space borne radiometry of the Earth’s atmosphere. Waveguide diplexing is a lower volume alternative to a quasi-optical, i.e., frequency selective surface based, system. The two channels considered are 164-167 GHz and 175-191 GHz. The diplexer comprises a Y junction with two waveguide-cavity filters. Two high-precision fabrication technologies have been utilized: computer numerical control (CNC) machining and 3D printing. Two units were CNC machined as brass split-blocks and a third was 3D printed monolithically in stainless steel by a micro laser sintering process. The latter is an innovative structure that incorporates the diplexer with the waveguide flanges. All devices were gold coated to reduce loss. Measured insertion losses in the two channels were 0.6 and 0.34 dB for the CNC-machined diplexers and 1.8 and 0.8 dB for the 3D printed diplexer. The maximum frequency shifts from design were 0.695 GHz in the CNC-diplexers and 1.55 GHz in the 3D printed diplexer.

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CNC-Machined and 3D-Printed Metal G-band Diplexers for Earth Observation Applications

Abstract

Bibliographical note

Keywords

ASJC Scopus subject areas

Access to Document

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Projects

Towards a 3D Printed Terahertz Circuit Technology

10 MHz to 1.1 THz Vector Network Analyser

Cite this