Evaluation of a Rapid Manufacturing Approach for Rectangular Waveguide Filters up to 1.1 THz

This work explores a rapid design and manufacturing approach to realize complex 3D pillar type filter and transmission line structures for applications in the 220 GHz – 325 GHz range, which cannot be economically reproduced by conventional machining processes or present rapid prototyping methods. The significance of this investigation is that at THz frequencies, the exact conductor shape and surface roughness have a significant electrical effect and any variations result in an important disagreement between the modelled and measured characteristics. This is a proof of concept validation of a multistage manufacturing approach that is aimed at paving the way to a range of THz passive waveguide components.