In this contribution, the design and manufacturing of an all-metal coaxial-line X-band bandpass filter is discussed. The device is 3D-printed as a self-supported structure without any dielectric inside the coaxial. The mechanical support between the inner and outer coaxial-line conductors is provided by means of $\lambda /4$ short-circuited stubs, which are also used in the bandpass filter design. The real transmission zeros (TZs) produced by the short-circuited stubs are responsible for a high filter selectivity. In order to enhance the filter performance, a second stage consisting in a coaxial-line stepped-impedance low-pass filter is integrated in the design to provide the rejection level required for the out-of-band behaviour. Following our design method, the bandpass and low-pass filters are designed separately, and a final matching step is performed to connect both and to achieve the aimed frequency specifications. In this way, a monoblock coaxial filter with very good in-band and out-of-band performance can by obtained by using an additive manufacturing (AM) procedure. Only the input/output (I/O) coaxial connectors will need to be assembled to the filter to perform the frequency measurements. The filters in this work can be seen as a first proposal towards more complex multi-functional monoblock structures using additively-manufactured coaxial technology, for highly-integrated RF chains. Other expected benefits beyond the compactness or lightweight are an increased RF shielding, electrostatic discharge risk reduction, and Passive Intermodulation (PIM) protection. In the paper, a prototype with a passband between 8 and 12 GHz is designed and manufactured, using a bandpass filter with three stubs and an integrated 15th-order low-pass filter, providing rejection for spurious frequencies up to 30 GHz. The filter is manufactured using Selective Laser Melting (SLM) and measurements show an excellent agreement with the simulations.

A refinement for the computation of the rigorous part of the multi-level fast multipole method (MLFMM) of analyzing volumetric objects is presented. A scheme based on the fast Fourier technique (FFT) is proposed with the objective of reducing the computational resources required to accurately analyze large homogeneous and non-homogeneous dielectric volumes. In order to reduce the memory requirements, the storage of the near-field terms of the method of moments (MoM) matrix is performed only for the positions corresponding to a parallelepiped with the size of the level 1 block of the MLFMM, computed with the vacuum permittivity, taking advantage of the Toeplitz symmetry present in regular hexahedral meshes. The FFT avoids applying the near-field MoM matrix in the iterative solution process. The application of this approach results in huge improvements in terms of memory usage, but also a speeds up the iterative solution process because the use of three-dimensional (3D) FFTs is very efficient for computing convolutions when the number of unknowns of the problems becomes very large as happens in volumetric problems. We also propose a new approach for the numerical treatment of the transition of the dielectric permittivity between different dielectrics or between a dielectric and a free space. To validate the computation technique, the radar cross section (RCS) of several dielectric bodies is computed using the classical MLFMM approach and it is compared with the presented FFT-based-MLFMM solution. The results demonstrate that the efficient memory and computation time usage of the proposed approach.

A new class of wideband bandpass filters based on using thick metallic bars as microwave resonators is presented in this work. These bars provide a series of advantages over fully planar printed technologies, including higher coupling levels between resonators, higher unloaded quality factors QU, and larger bandwidths implemented with compact structures. In comparison to dielectric and waveguide resonators filters, higher bandwidths together with lower weight and footprint reduction are achieved with the proposed thick bars technology. Moreover, thick bar resonators can easily be coupled to an additional resonance excited in a box used for shielding, allowing to realize transversal topologies able to implement transmission zeros at desired frequencies. To illustrate the capabilities of this technology, three microwave filters with different topologies have been designed. One of the designed filters has been manufactured and tested using copper bars inside an aluminum housing partially filled with Teflon. Measured data demonstrates a fractional bandwidth of FBW = 32%, spurious free range SFR > 50%, unloaded quality factor of QU = 1180, insertion losses over 0.16 dB and return losses over 20 dB, without requiring any post-tuning operation on the prototype. This result confirms the exciting performance of the proposed technology for wideband applications.

In this contribution, we describe the design of bandpass filters using evanescent mode waveguides and dielectric resonators implemented with additive manufacturing techniques. Two C-band Chebyshev evanescent mode waveguide filters of order five have been designed using a low cost commercial dielectric material (ABSplus), widely used by Fused Deposition Modeling (FDM) 3D printers. The housings of the filters have been manufactured using traditional computer numerical control (CNC) machining techniques. Practical manufacturing considerations are also discussed, including the integration of dielectric and metallic parts. We first discuss two breadboards using two different resonator geometries. We then demonstrate how different transfer functions can be easily implemented by changing the 3D printed parts in the same metallic housing. Breadboards show fractional bandwidths between 3% and 4.6% with return losses better than RL = 18 dB, and spurious free ranges of SFR = 1 GHz. Insertion losses are better than IL = 4.3 dB. Even though dielectric losses from the plastic material are shown to be high, the measured results are quite satisfactory, thereby clearly showing that this strategy maybe useful for the fast production of low cost microwave filters implementing complex geometries. (C) 2020 Elsevier GmbH. All rights reserved.

In this work, a refinement of the classical coupled-cavity filter design technique is presented. This refinement consists of a central frequency correction when calculating inter-resonator cavity couplings. The correction introduced is specially critical when 3D shapings are applied to empty cavities, since both resonators and couplings become more dispersive, and frequency tuning is harder due to an increased sensitivity with the resonator geometry. To validate the design approach, a filter design with shaped cavities is realised, where it can be seen that the traditional design technique leads to a starting point which is significantly far from the target specifications. However, the use of the new technique increases the accuracy of its initial response, allowing a simpler final optimization process. The technique presented can have big impact in the efficient design of future filter structures, where 3D shapings are applied to improve performances.