Horizon Microtechnologies is pleased to announce that it will be giving a webinar on the J.A.M.E.S platform on the 31st July 17.00 – 18.00 CEST. Register here
The webinar will be looking at how next generation waveguide-based RF (Radio Frequency) components can be produced via the use of micro-3D printing and the company’s proprietary metal coating, HMT-Metal (with which copper layers can be applied very evenly and conformally to a variety of component shapes and materials).
Waveguide-based RF components are specialised structures used to guide electromagnetic waves from one point to another with minimal loss of energy and signal degradation. These waveguides are typically hollow tubes with highly conductive inside surfaces, and are traditionally made from metals like brass, copper or aluminium.
Andreas Frölich, CEO at Horizon says, “Manufacturing waveguide-based RF components with traditional production technologies presents several significant challenges, particularly when dealing with the high precision and tolerances required for effective performance. One of the primary issues is the necessity for extremely tight tolerances. For instance, at D-Band frequencies, a tolerance of 33 micrometres on the dimensions is considered the least demanding and surfaces need to be smooth on the single micrometre scale. Achieving this consistently is difficult with conventional machining techniques the more complex the desired waveguide profile becomes. Traditional machining processes often struggle with maintaining these stringent tolerances over the entire length of the waveguide, leading to potential inconsistencies in the component's performance.”
Another major challenge is the difficulty of machining complex internal features into solid metal tubes. Many advanced RF components require intricate internal structures, such as lamellas, ridges or irises to achieve specific signal processing functions. Traditional machining processes, such as milling or drilling, are not well-suited for creating these detailed features inside a solid tube. The inability to directly access the internal surfaces makes it nearly impossible to machine these features accurately. This limitation often forces manufacturers to use alternative methods, such as assembling the waveguide from two halves in an approach known as split-block technology. While split-block technology allows for better access to the internal surfaces, it introduces its own set of challenges, with misalignment in assembly of the two halves resulting in signal degradation or interference, compromising the performance of the RF component.
Frölich continues: “During the upcoming webinar we will be detailing how micro-AM produced plastic parts coated with our Horizon-HMT copper coating can disrupt the waveguide-based RF components sector. Using plastic micro-AM to make such components presents several key advantages, addressing many of the manufacturability challenges encountered by traditional production methods. One of the primary benefits is the ability to achieve high precision and intricate geometries that are difficult or impossible to create with conventional machining. Micro-AM processes can produce complex internal features, such as lamellas, with the required precision and consistency, ensuring optimal performance of the RF components. This precision is particularly crucial at high frequencies, such as D-Band, where even small deviations can significantly impact the component's functionality.”
Micro-AM also facilitates component consolidation, allowing multiple parts to be manufactured as a single, integrated unit instead of assembling them using the bulky flanges found on traditional components. This reduces the overall size and weight of the components, which is beneficial in applications where space and weight are at a premium, such as in aerospace and satellite communications. By eliminating the need for assembly of separate parts, micro-AM reduces the potential for performance deficits introduced by alignment tolerances. The precise control offered by micro-AM ensures that all features are perfectly aligned from the outset, enhancing the reliability and performance of the final product.
Frölich concludes: “We will describe various case studies which show the successful use of coated micro-AM parts in mm-wave applications. For example, we undertook rigorous functional testing to prove the effectiveness of our HMT-Metal coating process for making high frequency D-Band horn antenna via 3D printing and waveguide transitions. Horizon’s devices performed as well as conventionally built ones, removing many of the reservations that 3D printed devices are often faced with. This proves that some very interesting opportunities exist as companies requiring mm-wave components can now exploit the process advantages of micro-AM by partnering with Horizon as their development and manufacturing partner. For example, the antenna weighed only a sixth of its conventional counterpart and took up 15% less space.”
