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Abstract
This paper characterizes the effective conductivity of lossy metal materials fabricated with additive manufacturing processes at microwave frequencies using a resonant cavity approach. Specifically addressed is the powder bed fusion additive manufacturing process utilizing AlSi10Mg material at Ku-band. The details of the procedure for converting device parameters that characterize the resonant cavity to material properties are given. Trade-offs between the precision of the conductivity and the quality factor of the cavity are discussed relevant to the design of the cavity. A best-fit matching procedure is made between the measured response of the manufactured cavities and the simulated results. The conductivity with statistical deviation for various fabricated cavities from different vendors is reported. Examples of various designs of fabricated prototype waveguide feed components are presented. The predicted and measured performance of each component is compared, validating the process.
Highlights
The term additive manufacturing (AM) includes many processes that use many different types of base materials
Additive manufacturing processes allow for the fabrication of structures that are very difficult if not impossible to build by other means
We found a strong correlation between the magnitude of the transmission at resonance and the conductivity, σ, and the waveguide height, b
Summary
The term additive manufacturing (AM) includes many processes that use many different types of base materials. Additive manufacturing processes allow for the fabrication of structures that are very difficult if not impossible to build by other means. Examples of such components include: shaped sub-reflectors, waveguide feeds, ortho-mode junctions, polarizers, filters, diplexers, couplers, etc [3]–[8]. One major advantage of the additive manufacturing processes is the ability to create monolithic structures in contrast to assembling multiple parts. Such structures advantageously lack seams and joints, since even the smallest gap, at microwave frequencies, can disrupt or alter the flow of current.
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