Additive manufacturing of Ku/K‐band waveguide filters: a comparative analysis among selective‐laser melting and stereo‐lithography

This study describes an experimental research activity on the manufacturing of passive waveguide components by means of two additive technologies, namely the selective‐laser melting and the stereo‐lithography processes. The former is a power‐bed fusion process, for which aluminium, titanium, and steel powders have been considered in this study. The latter is based on the photopolymerisation of a resin vat. This technology has been applied in conjunction with an acrylonitrile–butadiene–styrene‐like polymer and a subsequent electrolytic copper plating for the metallisation of the internal channels. Wideband filters operating in Ku/K band have been developed as benchmarks, for which detailed comparisons between simulations and measurements are reported.