Note: three-dimensional stereolithography for millimeter wave and terahertz applications

Area of Science:

• Materials Science
• Electromagnetics
• Additive Manufacturing

Background:

• Traditional manufacturing methods for millimeter and terahertz (THz) passive components often limit design complexity and increase production times.
• The need for advanced passive components in millimeter and THz applications necessitates innovative fabrication techniques.

Purpose of the Study:

• To introduce and evaluate a novel manufacturing approach for passive components operating in the millimeter and THz frequency ranges.
• To demonstrate the capability of 3D stereolithography for creating complex metal-coated polymer structures.

Main Methods:

• Utilizing 3D stereolithography to fabricate polymer substrates with intricate geometries.
• Applying metal coatings to the 3D-printed polymer structures to create functional passive electromagnetic components.
• Testing the performance of fabricated components at 92.5, 140, and 170 GHz.

Main Results:

• Successfully manufactured complex shapes such as corrugated horns and mirrors using the proposed method.
• Demonstrated the feasibility of producing functional passive components for millimeter and THz waves.
• Verified component performance through testing at specified high frequencies.

Conclusions:

• 3D stereolithography of metal-coated polymers presents a versatile and efficient manufacturing solution for millimeter and THz passive components.
• This technique significantly enhances design flexibility and reduces manufacturing lead times for complex electromagnetic devices.