A monolithic vertical integration concept for compact coaxial-resonator-based bandpass filters using additive manufacturing

This paper reports on a compact, low-cost and low-loss monolithic integration concept for additively-manufactured coaxial-resonator-based bandpass filters (BPFs). Size compactness and low weight are achieved by vertically-stacking capacitively-loaded coaxial resonators and by monolithic integration that eliminates the need for assembly screws or fixtures. Furthermore, the proposed vertical integration concept allows for: i) flexible cross couplings to be realized enabling highly-selective transfer functions through transmission zero (TZ) generation and ii) for fairly complex geometries to be manufactured using low-cost stereolithography apparatus (SLA). For proof-of-concept demonstration purposes, a two-pole BPF with fractional bandwidth (FBW) of 8.5% and a three-pole/one-TZ BPF with FBW 6.2% at 3.8 GHz were designed, SLA-manufactured and measured. They exhibited low-levels of insertion loss ( 1,833 and wide spurious-free operation

Additive Manufacturing of RF Waveguide Components

The exponential growth of publications, in the last years, on the use of additive manufacturing (AM) technologies in the microwave field proves the increasing interest of research institutions and industries in these techniques. Some advantages of AM with respect to conventional machining are weight reduction, design flexibility, and integration of different functionalities (electromagnetic, thermal, and structural) in a single part. This chapter presents the most employed AM technologies for the manufacturing of RF waveguide components. First, an overview of the AM processes is discussed with particular care on material properties and post-processing. Then, an extensive survey on microwave-guided components fabricated by AM processes published in literature is shown

Advanced direct metal 3D printed passive components for wireless communications and satellite applications

This thesis presents the design of advanced microwave passive filters, antennas, and antenna arrays using direct metal 3D printing technology. These work all incorporate the printing technology into the RF component design process, demonstrating the potential possibilities of direct metal 3D printing in the investigation and fabrication of passive microwave components with irregular shapes but attractive features. This thesis's works involved an extensive frequency range that starts with investigating S-band filters and then extends to C-band and Ku-band filters and antennas design. It is well known that in S- and C- band radio frequency (RF) applications that miniaturization is a critical factor for RF devices besides high performances. For this reason, the first project in this thesis proposed a novel compact waveguide loaded air slots resonator for designing inline bandpass filters. As a result, the designed filters not only have a smaller size than coaxial ones but also have controllable transmission zeros with inline structures. Since the air slots resonator is loaded inside the cavity, it is difficult to fabricate by conventional methods, but accessible by 3D printing technique with appropriate self-support structures. The fabrication quality was reflected by the mechanical and RF property measurements, which first demonstrated the advantage of using 3D printing technique to fabricate components with complex structures. The second project presents a compact high-Q fan-shaped folded waveguide resonator, which is applied to successfully design one C-band filter and filtering antenna. High performance RF properties and easy-to-print structures are always considered together. Accordingly, this work proposed and validated novel slots cross negative coupling topology of the filter and novel filtering antenna theory. Also, each of the designed components has better self-supported structures that can be printed with only two pieces, which highly reduced assembly processes and errors. Furthermore, the RF properties from measurement results further demonstrated that the reliability of the metal 3D printing technology for C-band RF applications. The concepts of the third project are extended from the second project but replaces the folded waveguide resonator with a metal strong coupling resonator (MSCR). The MSCR allows for even further compact dimensions while maintaining a high Q value of over 1000. It also allows producing mixed electrical-magnetic coupling by the curving coupling metal pairs intentionally. Except for the desired RF properties, the designed filter based on the MSCR can be printed as a whole even with complex inner circuits structures. Furthermore, the MSCR was integrated with the helical antenna using the proposed theory presented in the second project. Although the helical antenna belongs to the electrical-small antenna, the designed filtering antenna still has a high transmission efficiency of more than 95% and a 6 dBi realized gain concerning its less than quarter-wavelength. In addition, the filtering antenna has five helical radiation elements and one filter prototype but was printed with only three pieces, which showed the advantages of the direct metal 3D printing technology again. The fourth and the last project introduces a Ku-band slots antenna array application based on the sine corrugated waveguide resonator. Similar to previous projects, advanced RF performances were pursued in this project, in addition to demonstrating the use of 3D printing technology to fabricate compact and specific structures. The designed antenna array achieved a higher gain, wider band, and more simple feeding networks. The mode analysis method based on the EM software CST was applied to guide the design since no related formulas were available. The designed model was printed with two pieces and was measured thoroughly. The measured surface roughness, in-band responses, and radiation patterns showed promising results for the sine corrugated waveguide and 3D printing technology in satellite applications. In general, this thesis researched and proved the reliability and advantages of direct metal 3D printing technology in designing and fabricating advanced microwave passive components below the Ku-band. It should be mentioned that the designed passive components in this thesis can be easily re-designed/re-configured and applied on the 5G wireless base station and satellite communication systems

Emerging Trends in Techniques and Technology as Applied to Filter Design

In the last decade, the filter community has innovated both design techniques and the technology used for practical implementation. In design, the philosophy has become "if you can't avoid it, use it", a very practical engineering approach. Modes previously deemed spurious are intentionally used to create in-line networks incorporating real or imaginary transmission zeros and also reduce the number of components and thus further miniaturize; spurious responses are re-routed to increase the passband width or stopband width, frequency variation in couplings is used to create complex transfer functions, with all of these developments using what was previously avoided. Clever implementations of baluns into passive and active networks is resulting in a new generation of noise-immune filters for 5G and beyond. Finally, the use of a diakoptic approach to synthesis has appeared an evolving approach in which small blocks ("singlets", "doublets", etc.) are cascaded to implement larger networks, (reducing the need for very complex synthesis), with this new approach promising a large impact on the implementation of practical structures. Filter technology has migrated towards "observe it and then adapt it", pragmatically repurposing tools not specifically originally intended for the applications. Combinations of surface wave and bulk wave resonators with L-C networks are improving the loss characteristics of filters in the region below 2 GHz. Lightweight alloys and other materials designed for spacecraft are being used in filters intended for space, to provide temperature stability without the use of heavy alloys such as Invar. Fully-enclosed waveguide is being replaced in some cases by planar and quasiplanar structures propagating quasi-waveguide modes. This is generically referred to as SIW (Substrate Integrated Waveguide). Active filters trade noise figure for insertion loss but perhaps will offer advantage in terms of size and chip-level implementation. Finally, the era of reconfiguration might be approaching, as the basic networks are evolving, perhaps lacking only the appearance of lower-loss, higher-IP solid-state tuning elements

BioMEMS

As technological advancements widen the scope of applications for biomicroelectromechanical systems (BioMEMS or biomicrosystems), the field continues to have an impact on many aspects of life science operations and functionalities. Because BioMEMS research and development require the input of experts who use different technical languages and come from varying disciplines and backgrounds, scientists and students can avoid potential difficulties in communication and understanding only if they possess a skill set and understanding that enables them to work at the interface of engineering and biosciences. Keeping this duality in mind throughout, BioMEMS: Science and Engineering Perspectives supports and expedites the multidisciplinary learning involved in the development of biomicrosystems. Divided into nine chapters, it starts with a balanced introduction of biological, engineering, application, and commercialization aspects of the field. With a focus on molecules of biological interest, the book explores the building blocks of cells and viruses, as well as molecules that form the self-assembled monolayers (SAMs), linkers, and hydrogels used for making different surfaces biocompatible through functionalization. The book also discusses: Different materials and platforms used to develop biomicrosystems Various biological entities and pathogens (in ascending order of complexity) The multidisciplinary aspects of engineering bioactive surfaces Engineering perspectives, including methods of manufacturing bioactive surfaces and devices Microfluidics modeling and experimentation Device level implementation of BioMEMS concepts for different applications. Because BioMEMS is an application-driven field, the book also highlights the concepts of lab-on-a-chip (LOC) and micro total analysis system (μTAS), along with their pertinence to the emerging point-of-care (POC) and point-of-need (PON) applications