This paper first reviews manufacturing technologies for realizing air-filled metal-pipe rectangular waveguides (MPRWGs) and 3-D printing for microwave and millimeter-wave applications. Then, 3-D printed MPRWGs are investigated in detail. Two very different 3-D printing technologies have been considered: low-cost lower-resolution fused deposition modeling for microwave applications and higher-cost high-resolution stereolithography for millimeter-wave applications. Measurements against traceable standards in MPRWGs were performed by the U.K.’s National Physical Laboratory. It was found that the performance of the 3-D printed MPRWGs were comparable with those of standard waveguides. For example, across X-band (8–12 GHz), the dissipative attenuation ranges between 0.2 and 0.6 dB/m, with a worst case return loss of 32 dB; at W-band (75–110 GHz), the dissipative attenuation was 11 dB/m at the band edges, with a worst case return loss of 19 dB. Finally, a high-performance W-band sixth-order inductive iris bandpass filter, having a center frequency of 107.2 GHz and a 6.8-GHz bandwidth, was demonstrated. The measured insertion loss of the complete structure (filter, feed sections, and flanges) was only 0.95 dB at center frequency, giving an unloaded quality factor of 152—clearly demonstrating the potential of this low-cost manufacturing technology, offering the advantages of lightweight rapid prototyping/manufacturing and relatively very low cost when compared with traditional (micro)machining.

3-D Printed Metal-Pipe Rectangular Waveguides

During the last decades, smart tactile sensing systems based on different sensing techniques have been developed due to their high potential in industry and biomedical engineering. However, smart tactile sensing technologies and systems are still in their infancy, as many technological and system issues remain unresolved and require strong interdisciplinary efforts to address them. This paper provides an overview of smart tactile sensing systems, with a focus on signal processing technologies used to interpret the measured information from tactile sensors and/or sensors for other sensory modalities. The tactile sensing transduction and principles, fabrication and structures are also discussed with their merits and demerits. Finally, the challenges that tactile sensing technology needs to overcome are highlighted.

https://www.mdpi.com/1424-8220/17/11/2653/pdf

Novel Tactile Sensor Technology and Smart Tactile Sensing Systems: A Review.

Three-dimensional-printing technologies have been receiving great attention for a wide variety of applications in recent years for cost effectiveness, eco-friendliness, and process simplicity in complicated structures. This paper describes the challenges and solutions of applying 3-D-printing technologies in fabricating passive millimeter-wave (mmWave) and terahertz (THz) devices. First, we review the state-of-the-art dielectric 3-D-printed passive mmWave and THz devices. Then, we focus on our novel 3-D-printed metallic passive mmWave and THz devices such as horn antennas and waveguides. Next, we analyze the dimensional tolerance and surface roughness of various 3-D-printing technologies in order to provide a guide for choosing an appropriate technology for specific applications. Finally, we summarize the current work and identify the future studies in material powder refinement, surface treatment, optimization of the print process, development of hybrid dielectric and metallic 3-D-printing technology for realizing not only simple mmWave and THz devices but also sophisticated mmWave and THz systems.

Investigation on 3-D-Printing Technologies for Millimeter- Wave and Terahertz Applications

This paper presents two W-band waveguide bandpass filters, one fabricated using laser micromachining and the other 3-D printing. Both filters are based on coupled resonators and are designed to have a Chebyshev response. The first filter is for laser micromachining and it is designed to have a compact structure allowing the whole filter to be made from a single metal workpiece. This eliminates the need to split the filter into several layers and therefore yields an enhanced performance in terms of low insertion loss and good durability. The second filter is produced from polymer resin using a stereolithography 3-D printing technique and the whole filter is plated with copper. To facilitate the plating process, the waveguide filter consists of slots on both the broadside and narrow side walls. Such slots also reduce the weight of the filter while still retaining the filter’s performance in terms of insertion loss. Both filters are fabricated and tested and have good agreement between measurements and simulations.

/pdf/w-band-waveguide-filters-fabricated-by-laser-micromachining-57fncp8lxh.pdf

$W$ -Band Waveguide Filters Fabricated by Laser Micromachining and 3-D Printing

This paper demonstrates a two-layer SU8 photoresist micromachining technology that has similar performance to conventionally machined metal. The technology is demonstrated in the WR-3 band (220-325 GHz). Three different WR-3 band circuits, namely a WR-3 band straight through waveguide, a bandpass filter and a dual-band filter are demonstrated. For the measurements, a conventionally precision machined metal block was used for the WR-3 band waveguide and the bandpass filter to achieve good calibration and accurate interconnection with standard waveguide flanges; whereas, for the dual-band filter, two back-to-back right-angle bends are added in order to achieve accurate, reliable waveguide interconnection without using the metal block. A measured average insertion loss of 0.03 dB/mm has been achieved for the 14.97 mm long straight through waveguide. This is comparable to the loss of around 0.02 dB/mm for a standard metal waveguide at this frequency. The fifth-order waveguide filter exhibits an 8% 3 dB bandwidth at a central frequency of around 300 GHz. The minimum passband insertion loss was measured to be around 1 dB and the return loss was better than 10 dB throughout the passband. The filter results showed a notable improvement over those obtained from the separate SU8 layer technique that was also used to make the same devices for comparison. To further demonstrate the advantages of the new two-layer SU8 micromachining technique, the dual-band filter included isolated regions in the waveguide channels that would have not been possible for micromachining using the previous separate single layer technique. The performance of the micromachined dual band filter was excellent in terms of very low insertion losses on both passbands.

WR-3 Band Waveguides and Filters Fabricated Using SU8 Photoresist Micromachining Technology

A micromachined 300-GHz slotted waveguide antenna is demonstrated using a simple fabrication technique based on metal-coated SU-8 thick resist. The antenna is designed to be built from a four-layer structure of equal layer thickness. It is fully characterized, and the measured radiation patterns show excellent agreement with the simulation. An H-plane matched right-angle bend is integrated in the antenna in order to achieve reliable and accurate connection with standard waveguide flange. The micromachined antenna is directional and low-profile and may find applications in low-cost sensors and radars.

Micromachined 300-GHz SU-8-Based Slotted Waveguide Antenna

This paper presents the design and performance of a low-loss rectangular air-filled coaxial cable. A high-precision micromachining technique is used to fabricate the cable. It is assembled by bonding together five layers of gold-coated SU-8 photoresist fabricated using the ultraviolet photolithographic technique. As the cable is air filled, both the dielectric and radiation losses are negligible. The cross coupling is also very weak between the cable and other parts of the circuit in a system. These advantages make the proposed cable a very good candidate for low-cost high-performance miniaturized transmission lines. The cable is designed to work in the frequency range of 14-36 GHz, which covers the whole JC-band. The size of the cable is only 8.9 mm times 8.6 mm times 1.5 mm and the measured minimum insertion loss of the as-made cable is approximately 0.6 dB. The return loss is better than 15 dB in the passband.

Design and High Performance of a Micromachined $K$ -Band Rectangular Coaxial Cable

A micromachined W-band through waveguide together with a passband filter embedded with a pair of H-plane bends is presented here. The novel design of the bend enabled direct and accurate connection between the micromachined circuit and standard waveguide flanges. The devices were fabricated using thick SU-8 photoresist technology. They were constructed with six gold- or silver-coated SU-8 layers, each of a thickness of 0.635 mm. These layers were then bonded on top of each other to form the waveguide and filter. A measured average insertion loss of 0.5 dB or 0.0278 dB/mm has been achieved by the 18 mm long through waveguide, and the return loss is better than 18.8 dB in the whole W-band. The asymmetrical capacitive irises coupled filter shows a -3 dB bandwidth of 8.61 GHz at a central frequency of 88.47 GHz. The passband insertion loss was measured to be between 0.97 and 1.1 dB and reflection loss is better than 15 dB. This performance demonstrates the potential of employing this micromachining and multi-layered technique to fabricate millimetre and submillimetre waveguide components.

Micromachined W-band waveguide and filter with two embedded H-plane bends

Wideband millimeter-wave branch-line couplers have been demonstrated using micromachined air-filled rectangular-coaxial lines supported by quarter-wavelength stubs. The coaxial lines are constructed by bonding five layers of gold-plated silicon or SU8 slices. The measured coupler shows an insertion loss of 3.2-4.0 dB in the coupled and thru ports between the frequencies 31.3-47.6 GHz. The isolation is better than 12.8 dB, and the return loss less than -10 dB. In addition to providing support, the stubs enhance bandwidth when properly placed.

Maolong Ke

Papers

WR-3 Band Waveguides and Filters Fabricated Using SU8 Photoresist Micromachining Technology

Micromachined 300-GHz SU-8-Based Slotted Waveguide Antenna

Design and High Performance of a Micromachined $K$ -Band Rectangular Coaxial Cable

Micromachined W-band waveguide and filter with two embedded H-plane bends

Micromachined Millimeter-Wave Rectangular-Coaxial Branch-Line Coupler With Enhanced Bandwidth