3d Printed Waveguides: a Revolution in Low Volume Manufacturing for the 21st Century

3D printing is a disruptive technology, offering the inherent capabilities for creating truly arbitrary 3D structures, with low manufacturing costs associated with low volume production runs. This paper provides an overview of the current progress in 3D printing of metal-pipe rectangular waveguide (MPRWG) components, from 10 GHz to 1 THz, at Imperial College London. First, measurements performed at the UK National Physical Laboratory demonstrate that 3D printed MPRWG performance is comparable to standard commercial waveguides at X-band and W-band. Then, a fully 3D printed X-band dielectric flap tuneable phase shifter and W-band 6thorder inductive iris bandpass filter are demonstrated experimentally. Finally, an opticallycontrolled 500 GHz IQ vector modulator will also be presented; packaged laser diodes and high resistivity silicon implants are integrated within a hybrid 3D printed split-block module, representing a paradigm shift in additive manufacturing for realizing tuneable THz applications.