Open Access
Metal 3D printing for RF/microwave high-frequency parts
(Springer, 2022) Martín Iglesias, Petronilo; Gómez Laso, Miguel Ángel; Lopetegui Beregaña, José María; Teberio Berdún, Fernando; Arregui Padilla, Iván; Marechal, M.; Calves, P.; Hazard, M.; Pambaguian, L.; Brandao, A.; Rodríguez Castillo, S.; Martin, T.; Percaz Ciriza, Jon Mikel; Iza, V.; Martín-Iglesias, Santiago; Ingeniería Eléctrica, Electrónica y de Comunicación; Ingeniaritza Elektrikoa, Elektronikoaren eta Telekomunikazio Ingeniaritzaren
Space Systems have been historically characterised by high performance, high reliability and high cost. Every new generation of space systems tends to improve performance, keep as much as possible reliability, speeding the lead time and lower the cost. Aggressive approach is nowadays followed by some of the players of the new space ecosystem where, for instance, reli- ability can be relaxed thanks for the in-orbit redundancy or robustness to failures by having a constellation with a high number of satellites. This push towards the technology and system limit requires to investigate new methods for the manufacturing of RF/Microwave parts. RF devices such as those based on waveguide structures, benefit from an additive manufacturing approach in terms of radio frequency (RF) performance and compactness. However each manufacturing approach comes with specific features and limitations which need to be well understood and, in some cases, even taking advantage of them. This paper provides a short review of some of the RF/Microwave parts already manufactured using this technology. The paper will focus mainly on metal 3D printing parts since this technology is, at the moment, well accepted by the space community.
Open Access
Improvement of corona breakdown threshold (peak power handling) in smooth-profiled microstrip filters
(2022) Ahmad, Jamil; Hussain, Jabir; Arregui Padilla, Iván; Martín Iglesias, Petronilo; Arnedo Gil, Israel; Gómez Laso, Miguel Ángel; Lopetegui Beregaña, José María; Ingeniería Eléctrica, Electrónica y de Comunicación; Institute of Smart Cities - ISC; Ingeniaritza Elektrikoa, Elektronikoaren eta Telekomunikazio Ingeniaritzaren
In this paper, the PPHCs of two filter design techniques, stepped-impedance (SI) and smooth-profile (SP), are presented for four design prototypes. Smooth-profiled filters feature smooth variations in the characteristic impedance profile, avoiding sharp edges, which accumulate electric fields. The absence of sharp edges in SP reduces the voltage magnification factor, which in turn improves the PPHC of the filter. The phenomenon of electric fields accumulation at the sharp corners of the SI filters is presented and compared with smooth transitions in SP filters. Furthermore, 1D graphs of electric field intensity are presented along the strip contour of the microstrip lines. Finally, SPARK3D results clearly demonstrate that SP filters can handle higher peak powers than their SI counterparts between critical pressure and ambient pressure, for all the studied designs.
Open Access
Synthesis of rectangular waveguide filters with smooth profile oriented to direct metal additive manufacturing
(IEEE, 2023) Percaz Ciriza, Jon Mikel; Hussain, Jabir; Arregui Padilla, Iván; Teberio Berdún, Fernando; Benito Pertusa, David; Martín Iglesias, Petronilo; Arnedo Gil, Israel; Gómez Laso, Miguel Ángel; Lopetegui Beregaña, José María; Ingeniería Eléctrica, Electrónica y de Comunicación; Institute of Smart Cities - ISC; Ingeniaritza Elektrikoa, Elektronikoaren eta Telekomunikazio Ingeniaritzaren
In this paper, a novel design method for rectangular waveguide filters intended for fabrication using direct metal additive manufacturing is proposed. The synthesized filters will feature a smooth profile that allows us to fabricate them orienting the filter propagation axis in the vertical building direction, achieving an optimum configuration for direct metal additive manufacturing fabrication. The novel design method is valid for any all-pole transfer function, which is initially implemented with a commensurate-line distributed unit element prototype. The impulse response of that initial prototype is then properly interpolated to obtain the target response for a smooth-profiled filter with similar length and profile excursion. Finally, the target impulse response just generated is implemented in rectangular waveguide technology employing a novel inverse scattering synthesis technique that relies on the coupled-mode theory to model the electromagnetic behavior of the waveguide filter. The novel inverse scattering synthesis technique is general and also valid for the case of filters with very high rejection levels, which is of great relevance in rectangular waveguide technology. A Ku-band low-pass filter with stringent satellite specifications is designed using the proposed method, fabricated by means of a direct metal additive manufacturing technique, and measured with a vector network analyzer. A very good agreement is achieved between the simulated and measured results, fulfilling the required specifications and demonstrating the feasibility and performance of the novel design method.
Open Access
Diseño robusto de filtros paso-banda de banda W en tecnología Gap Waveguide impresos en 3D
(URSI, 2023) Santiago Arriazu, David; Tamayo-Domínguez, Adrián; Gómez Laso, Miguel Ángel; Lopetegui Beregaña, José María; Fernández-González, José Manuel; Martínez, Ramón; Arregui Padilla, Iván; Ingeniería Eléctrica, Electrónica y de Comunicación; Institute of Smart Cities - ISC; Ingeniaritza Elektrikoa, Elektronikoaren eta Telekomunikazio Ingeniaritzaren
A 3D-printed bandpass filter for the W-band is proposed in this work. The use of the higher-order TE10n modes in groove gap waveguide (GGW) technology is analyzed and shown to ease the manufacturing requirements. The design example is a 5th-order Chebyshev filter at 94 GHz, which is easily fabricated by stereolithographic (SLA) 3D-printing (an additive manufacturing technique). The filter is silver coated once it is printed. Excellent measured performance is reported. The combination of higher-order modes, GGW technology and SLA 3D-printing seems to be a promising way of fabricating filters in W-band for high-capacity high data-rate communication systems.
Open Access
General synthesis of tapered matching sections for single mode operation using the coupled-mode theory
(IEEE, 2019) Percaz Ciriza, Jon Mikel; Arnedo Gil, Israel; Arregui Padilla, Iván; Teberio Berdún, Fernando; Martín Iglesias, Petronilo; Gómez Laso, Miguel Ángel; Lopetegui Beregaña, José María; Ingeniería Eléctrica, Electrónica y de Comunicación; Ingeniaritza Elektrikoa, Elektronikoaren eta Telekomunikazio Ingeniaritzaren
In this paper, a novel and general method to synthetize microwave waveguide tapers intended for single mode operation is proposed. The technique is based on the use of an exact series solution of the inverse scattering synthesis problem. An additional strategy necessary for dealing with waveguides where the propagation constant varies with the position is included. The coupled-mode theory is employed to model the electromagnetic behavior of the taper with the inherent mismatch caused by the connection of the waveguides with different cross-sections. The novel method allows us to synthesize the (classical) transmission line taper functions of Klopfenstein and Hecken, making them suitable for general waveguide tapers with single mode operation. Additionally, a new type of taper functions, also suitable for general waveguide tapers, is presented. The novel functions are obtained by partially employing the frequency response of multisection transformers, resulting in fully smooth tapers that can offer shorter lengths than the classical proposals. The taper synthesis procedure is demonstrated in rectangular waveguide technology, by requiring realistic and challenging specifications for different cases with different waveguide cross-sections to be matched: height mismatch, width mismatch, and simultaneous height and width mismatch. Several prototypes of Klopfenstein, Hecken and novel function tapers have been fabricated in an aluminum alloy by means of an Additive Manufacturing technique (Direct Metal Laser Sintering). The simulation and measurement results obtained for the rectangular waveguide taper prototypes confirm the accuracy of the novel synthesis technique proposed.
Open Access
Robust tolerance design of bandpass filter with improved frequency response for Q-band satellite applications
(IEEE, 2021) Sami, Abdul; Teberio Berdún, Fernando; Miranda Santafé, Luis; Arnedo Gil, Israel; Martín Iglesias, Petronilo; Benito Pertusa, David; Lopetegui Beregaña, José María; Gómez Laso, Miguel Ángel; Arregui Padilla, Iván; Ingeniería Eléctrica, Electrónica y de Comunicación; Ingeniaritza Elektrikoa, Elektronikoaren eta Telekomunikazio Ingeniaritzaren
A rectangular waveguide bandpass filter for Q-band with simple fabrication is proposed in this letter. The design is based on the use of the first passband replica of commensurate-line stepped-impedance structures and achieves the suppression of their inherent low-pass response. In order to do it, the filter is implemented by rectangular waveguide sections with different widths and heights that can be analytically calculated. The technique is validated by a 9th order Chebyshev filter with passband between 40 and 43 GHz and fabrication yield equal to 84 % for a manufacturing error of ± 20 μm. The measured results of the prototype fabricated with CNC milling are in good agreement with the simulated ones.
Open Access
Enhancement of the peak power handling capability in microstrip filters by employing smooth-profiled conductor strips
(2023) Ahmad, Jamil; Hussain, Jabir; Arregui Padilla, Iván; Martín Iglesias, Petronilo; Arnedo Gil, Israel; Gómez Laso, Miguel Ángel; Lopetegui Beregaña, José María; Ingeniería Eléctrica, Electrónica y de Comunicación; Institute of Smart Cities - ISC; Ingeniaritza Elektrikoa, Elektronikoaren eta Telekomunikazio Ingeniaritzaren
This paper presents a design methodology that significantly increases the peak power handling capability (PPHC) of microstrip filters. The PPHC is limited in microstrip technology by the corona effect: a physical phenomenon caused by the ionization of the air under the presence of strong electric fields around the planar circuit. Microstrip filters with a low electric field strength in the air increases the corona threshold level, resulting in high PPHC. Conventional stepped impedance (SI) filters, which consist of cascaded step-shaped elements, exhibit sharp discontinuities. These geometric edges amplify the electric field strength in the air, consequently reducing the corona threshold. Our research group has recently reported a new synthesis technique that introduces a smooth-profile (SP) conductor strip. This SP strip eliminates any sharp discontinuities and significantly reduces the strength of the electric field. This paper focuses on the examination of the high power performance of 7th-order SP and SI low-pass filters. The cut-off frequency (fc) for both types of filters is set at 447.45 MHz, while the frequency for maximum stop-band rejection (fo) is 1 GHz. The findings indicate that the SP filter shows a notable enhancement in peak power handling capability (PPHC), with gains of 2.48 dB and 4.80 dB observed at critical pressure and ambient pressure, respectively.
Open Access
Routing with classical corrugated waveguide low-pass filters with embedded bends
(EMW Publishing, 2018) Teberio Berdún, Fernando; Percaz Ciriza, Jon Mikel; Arregui Padilla, Iván; Martín Iglesias, Petronilo; Lopetegui Beregaña, José María; Gómez Laso, Miguel Ángel; Arnedo Gil, Israel; Ingeniería Eléctrica y Electrónica; Ingeniaritza Elektrikoa eta Elektronikoa
A very simple design method to embed routing capabilities in classical corrugated filters is presented in this paper. The method is based on the calculation of the heights and lengths of the so-called filters design building blocks, by means of a consecutive and separate extraction of their local reflection coefficients along the device. The proposed technique is proved with a 17th-order Zolotarev filter whose topology is bent twice so that the input and output ports are in the same plane while preserving the in-line filters behaviour. This new filter allows the possibility of eliminating subsequent bending structures, reducing the insertion loss, weight, and PIM.
Open Access
Robust design of 3D-printed W-band bandpass filters using gap waveguide technology
(Springer, 2022) Santiago Arriazu, David; Tamayo-Domínguez, Adrián; Gómez Laso, Miguel Ángel; Lopetegui Beregaña, José María; Fernández-González, José Manuel; Martínez, Ramón; Arregui Padilla, Iván; Ingeniaritza Elektrikoa, Elektronikoaren eta Telekomunikazio Ingeniaritzaren; Institute of Smart Cities - ISC; Ingeniería Eléctrica, Electrónica y de Comunicación; Universidad Pública de Navarra / Nafarroako Unibertsitate Publikoa
In this paper, a W-band 3D-printed bandpass filter is proposed. The use of higher-order TE10n modes in groove gap waveguide (GGW) technology is evaluated in order to alleviate the manufacturing requirements. In addition to the use of higher-order modes, the coupling between them is analyzed in detail to improve the overall fabrication robustness of the component. This allows the implementation of narrow-band filters operating at millimeter-wave frequency bands (or above), which usually demand complex manufacturing techniques to provide the high accuracy required for this kind of devices. In order to show the applicability of the proposed method, a narrow-band 5th-order Chebyshev bandpass filter centered at 94 GHz, which can be easily fabricated by state-of-the-art stereolithographic (SLA) 3D-printing techniques followed by silver coating, is shown. Excellent measured performance has been obtained.
Open Access
Rectangular waveguide filters with meandered topology
(IEEE, 2018) Teberio Berdún, Fernando; Percaz Ciriza, Jon Mikel; Arregui Padilla, Iván; Martín Iglesias, Petronilo; Lopetegui Beregaña, José María; Gómez Laso, Miguel Ángel; Arnedo Gil, Israel; Ingeniería Eléctrica y Electrónica; Ingeniaritza Elektrikoa eta Elektronikoa; Gobierno de Navarra / Nafarroako Gobernua, 0011-1365-2017-000130
In this paper, a new topology for rectangular waveguide bandpass and low-pass filters is presented. A simple, accurate, and robust design technique for these novel meandered waveguide filters is provided. The proposed filters employ a concatenation of ±90° E-plane mitered bends (±90° EMBs) with different heights and lengths, whose dimensions are consecutively and independently calculated. Each ±90° EMB satisfies a local target reflection coefficient along the device so that they can be calculated separately. The novel structures allow drastically reduce the total length of the filters and embed bends if desired, or even to provide routing capabilities. Furthermore, the new meandered topology allows the introduction of transmission zeros above the passband of the low-pass filter, which can be controlled by the free parameters of the ±90° EMBs. A bandpass and a low-pass filter with meandered topology have been designed following the proposed novel technique. Measurements of the manufactured prototypes are also included to validate the novel topology and design technique, achieving excellent agreement with the simulation results.