Utilization of Additive Manufacturing for the Rapid Prototyping of C-Band RF Loads

TL;DR

This paper demonstrates the use of additive manufacturing to rapidly produce a C-band RF load prototype, validating its design through simulation and testing, and highlighting its potential for accelerating RF component development.

Contribution

It introduces a novel method for fabricating RF loads using additive manufacturing, specifically direct metal laser sintering of stainless steel, with successful testing at high power and specific frequency.

Findings

Achieved an S11 of -22.8 dB at 5.712 GHz

Successfully terminated a peak power of 8.1 MW

Validated the design through simulation and physical testing

Abstract

Additive manufacturing is a versatile technique that shows promise in providing quick and dynamic manufacturing for complex engineering problems. Research has been ongoing into the use of additive manufacturing for potential applications in radiofrequency (RF) component technologies. Here we present a method for developing an effective prototype load produced out of 316L stainless steel on a direct metal laser sintering machine. The model was tested within simulation software to verify the validity of the design. The load structure was manufactured utilizing an online digital manufacturing company, showing the viability of using easily accessible tools to manufacture RF structures. The produced load was able to produce an S$_{11}$ value of -22.8 dB at the C-band frequency of 5.712 GHz while under vacuum. In a high power test, the load was able to terminate a peak power of 8.1 MW. Discussion includes future applications of the present research and how it will help to improve the implementation of future accelerator concepts.