ABSTRACT This paper investigates a novel waveguide component design with dual functionality of mode conversion and power splitting. Because of its complex internal geometry which conventional fabrication methods cannot realize, additive manufacturing was explored, specifically selective laser melting. The end-to-end process of design, simulation, fabrication, and measurement will be discussed in detail. The said waveguide component converts between 4 rectangular waveguide TE10 mode and 1 circular waveguide TM01 mode. The 1 to 4 splitter was done while achieving low power splitting losses and mode conversion losses with low return losses. This allows for waveguide connections to be made between circular waveguides and rectangular waveguides at X-Band, which can be used for radars or satellite communication applications. The novelty of this component design comes from impedance matching between 4 rectangular waveguides operating in the fundamental mode and 1 single highly over-moded circular waveguide by means of coaxial rod and matching fins. All these are done while keeping the overall size small, compact, and lightweight.
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