45–110 GHz Quad-Ridge Horn With Stable Gain and Symmetric Beam

A quad-ridge horn antenna with stabilized gain and minimum difference between Eand H-plane half-power beamwidths (HPBWs) is demonstrated for operation over 45-110 GHz bandwidth. Multistep flaring and corrugations on a finite ground plane are applied to obtain stable radiation patterns with 16-dBi minimum gain over the entire range. The computational studies are validated through measurements of a 3-D printed prototype using the direct metal laser sintering (DMLS) process. Accurate fabrication with achieved surface roughness of <;1.7 μm of the fabricated antenna is verified with digital microscope. The obtained gain variation, VSWR, and HPBW variation with rotation and over 45-110 GHz bandwidth are below 1.7 dB, 1.7:1, and 9°, respectively. This work demonstrates that the DMLS is a viable fabrication process for wideband horn antennas at millimeter-wave frequencies.