3D Printing of a Monolithic K/Ka-Band Dual-Circular Polarization Antenna-Feeding Network

In this paper, a Ka/K-band antenna-feeding network in dual-circular polarization is reported. The design of the system was carried out in view of its monolithic manufacturing through selective laser melting in AlSi10Mg alloy. As a proof-of-concept for satellite telecommunication multi-beam applications, the feeding network operates in the K band (19.25, 20.75) GHz and in the Ka band (27.0, 29.0) GHz. The system provides four rectangular-waveguide ports and a common dual-polarized circular-waveguide port to be connected to the feed horn. The prototype exhibits measured values of in-band return loss better than 28 dB and a port-to-port isolation better than 19 dB (in polarization) and 50 dB (in frequency). The cross-polar discrimination is higher than 20 dB. In this regard, an elliptical-waveguide line was specifically designed and manufactured to recover a value higher than 30 dB in both frequency bands. The line can be easily integrated in the feed horn to be connected to the feeding-network thanks the ease of customization provided by 3D printing. The insertion losses are lower than 0.5 and 0.2 dB in the K and Ka bands, respectively. The weight of the prototype is approximately 130 g.