Ceramic Layer-By-Layer Stereolithography for the Manufacturing of 3-D Millimeter-Wave Filters

Three-dimensional (3-D) ceramic stereolithography has been developed and used to manufacture RF devices using periodic structures. To our knowledge, it is the first time that zirconia and high-performance Ba3ZnTa2O9ceramics are used with that process to manufacture high unloaded quality factor resonant structures and bandpass filters working in the Ka-band. A theoretical study on the performances of periodic arrangements of high-permittivity structures has been carried out and has led to the manufacture of a high unloaded quality factor cavity and narrow three-pole filter (1% bandwidth) measured at a working frequency of 33 GHz