scholarly journals Micro Metal Additive Manufactured Low-Loss Slotted Rectangular Waveguides Operating at 220-500 GHz

2021 ◽  
Vol 9 ◽  
Author(s):  
Zixian Wu ◽  
Guanghua Shi ◽  
Yang Yu ◽  
Xiaozhu Wen ◽  
Cheng Guo ◽  
...  

This paper reports the design, fabrication and measurement techniques for a set of low-loss slotted waveguides. The waveguides are fabricated based on a micro metal additive manufacturing technology. They were fabricated layer by layer in one piece without the need of post-fabrication assembly. As examples, straight waveguides in WR-3.4 (220-330°GHz) and WR-2.2 (330-500°GHz) bands were fabricated and tested. Measurement results show the insertion loss per unit length is 0.0615-0.122°dB/mm and 0.116-0.281°dB/mm, respectively.

Materials ◽  
2020 ◽  
Vol 13 (2) ◽  
pp. 255 ◽  
Author(s):  
Kevin Carpenter ◽  
Ali Tabei

One of the most appealing qualities of additive manufacturing (AM) is the ability to produce complex geometries faster than most traditional methods. The trade-off for this advantage is that AM parts are extremely vulnerable to residual stresses (RSs), which may lead to geometrical distortions and quality inspection failures. Additionally, tensile RSs negatively impact the fatigue life and other mechanical performance characteristics of the parts in service. Therefore, in order for AM to cross the borders of prototyping toward a viable manufacturing process, the major challenge of RS development must be addressed. Different AM technologies contain many unique features and parameters, which influence the temperature gradients in the part and lead to development of RSs. The stresses formed in AM parts are typically observed to be compressive in the center of the part and tensile on the top layers. To mitigate these stresses, process parameters must be optimized, which requires exhaustive and costly experimentations. Alternative to experiments, holistic computational frameworks which can capture much of the physics while balancing computational costs are introduced for rapid and inexpensive investigation into development and prevention of RSs in AM. In this review, the focus is on metal additive manufacturing, referred to simply as “AM”, and, after a brief introduction to various AM technologies and thermoelastic mechanics, prior works on sources of RSs in AM are discussed. Furthermore, the state-of-the-art knowledge on RS measurement techniques, the influence of AM process parameters, current modeling approaches, and distortion prevention approaches are reported.


2020 ◽  
Vol 143 (5) ◽  
Author(s):  
Joseph R. Kubalak ◽  
Alfred L. Wicks ◽  
Christopher B. Williams

Abstract The layer-by-layer deposition process used in material extrusion (ME) additive manufacturing results in inter- and intra-layer bonds that reduce the mechanical performance of printed parts. Multi-axis (MA) ME techniques have shown potential for mitigating this issue by enabling tailored deposition directions based on loading conditions in three dimensions (3D). Planning deposition paths leveraging this capability remains a challenge, as an intelligent method for assigning these directions does not exist. Existing literature has introduced topology optimization (TO) methods that assign material orientations to discrete regions of a part by simultaneously optimizing material distribution and orientation. These methods are insufficient for MA–ME, as the process offers additional freedom in varying material orientation that is not accounted for in the orientation parameterizations used in those methods. Additionally, optimizing orientation design spaces is challenging due to their non-convexity, and this issue is amplified with increased flexibility; the chosen orientation parameterization heavily impacts the algorithm’s performance. Therefore, the authors (i) present a TO method to simultaneously optimize material distribution and orientation with considerations for 3D material orientation variation and (ii) establish a suitable parameterization of the orientation design space. Three parameterizations are explored in this work: Euler angles, explicit quaternions, and natural quaternions. The parameterizations are compared using two benchmark minimum compliance problems, a 2.5D Messerschmitt–Bölkow–Blohm beam and a 3D Wheel, and a multi-loaded structure undergoing (i) pure tension and (ii) three-point bending. For the Wheel, the presented algorithm demonstrated a 38% improvement in compliance over an algorithm that only allowed planar orientation variation. Additionally, natural quaternions maintain the well-shaped design space of explicit quaternions without the need for unit length constraints, which lowers computational costs. Finally, the authors present a path toward integrating optimized geometries and material orientation fields resulting from the presented algorithm with MA–ME processes.


2021 ◽  
Vol 12 (2) ◽  
pp. 371-380
Author(s):  
Sally Cahyati ◽  
◽  
Haris Risqy Aziz

Rapid Prototyping (RP) is a manufacturing process that produces a 3D model CAD to be a real product rapidly by using additive manufacturing technology. In this case, the product will print layer by layer uses a 3D printer machine. The 3D printer requires slicer software to convert CAD data into data that a 3D printer machine can read. Research is done to analyze the effect of three kinds of slicer software on 3D printing objects on the accuracy and surface roughness of the product. The 3D model CAD is sliced using three different slicer software, namely Ideamaker, Repetier Host, and Cura. The slice model result from each slicer will be printed on a 3D printer machine with the same process parameters to be compared. Then the product's dimensional and surface roughness will be measured to determine the effect of each slicer on product quality. The best quality of the product reflected the most suitable slicer software for the 3D printing machine that used. The best results achieved by Cura slicer because it has resulted in small dimensional deviations (max 0,0308±0,0079) and stabile high surface roughness of the product (max 1,585+059).


Proceedings ◽  
2019 ◽  
Vol 27 (1) ◽  
pp. 24
Author(s):  
D’Accardi ◽  
Altenburg ◽  
Maierhofer ◽  
Palumbo ◽  
Galietti

One of the most advanced technologies of Metal Additive Manufacturing (AM) is the Laser Powder Bed Fusion process (L-PBF), also known as Selective Laser Melting (SLM). This process involves the deposition and fusion, layer by layer, of very fine metal powders and structure and quality of the final component strongly depends on several processing parameters, for example the laser parameters. Due to the complexity of the process it is necessary to assure the absence of defects in the final component, in order to accept or discard it. Thermography is a very fast non-destructive testing (NDT) technique. Its applicability for defect detection in AM produced parts would significantly reduce costs and time required for NDT, making it versatile and very competitive.


2015 ◽  
Vol 7 (3-4) ◽  
pp. 261-270 ◽  
Author(s):  
Václav Valenta ◽  
Thomas Spreng ◽  
Shuai Yuan ◽  
Wolfgang Winkler ◽  
Volker Ziegler ◽  
...  

Different types of bondwire interconnect for differential chip-to-antenna and single-ended chip-to-chip interfaces are investigated. Two differential compensation structures for various lengths of interconnects are designed and experimentally evaluated using dedicated transmit and receive radar modules operating across a 110–156 GHz band. Measurement results demonstrate that a fractional bandwidth of 7.5% and a minimum insertion loss of 0.2 dB can be achieved for differential interconnects as long as 0.8 mm. Design and measurement results of an extremely wideband low-loss single-ended chip-to-chip bondwire interconnect that features 1.5 dB bandwidth from DC to 170 GHz and insertion loss of less than 1 dB at 140 GHz are presented as well. The results show that the well-established wire-bonding techniques are still an attractive solution even beyond 100 GHz. Reproducibility and scalability of the proposed solutions are assessed as well.


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