Feasibility study on fabrication of Ka-band waveguides via 3D printing and post-metal coating

This study reports the fabrication result of a Ka-band waveguide for a low Earth orbit satellites using 3D printing and subsequent polymer metal coating. Electroless plating followed by electroplating proved effective in improving mechanical and adhesive characteristics. Both careful modification of the waveguide model and adjustment of the thickness of the Cu electroplating layer mitigated bowing issues during post-curing. The final Ka-band evaluation (26.5–30 GHz) showed an average S21 value of approximately 5.25 dB. Despite losses at the flange input and outlet, these results indicate the feasibility of the applied fabrication method for the use of Ka-band waveguides. Unlike existing studies focusing on Ku-band, this research emphasizes the challenging waveguide model for Ka-band, offering insights into SLA printing, post-curing methods, and metal coating on photopolymer surfaces.