Technological Investigation of Metal 3D Printed Microwave Cavity Filters Based on Different Topologies and Materials

Povilas Vaitukaitis, Kenneth Nai, Jiayu Rao, Mustafa S. Bakr, Jiasheng Hong

Research output: Contribution to journalArticlepeer-review

7 Citations (Scopus)
56 Downloads (Pure)


This paper presents metal 3D printed wideband bandpass filters based on a deformed elliptical cavity resonator. The resonator can produce a wide stopband response by realising arbitrary real-frequency transmission zero at prescribed frequencies. The design procedure of canonical filtering functions is detailed. Six design examples of bandpass filters are presented to validate the design methodology. Three of the designed filters were metal 3D printed using Selective Laser Melting in AlSi10Mg and commercially pure copper for experimental verification. Copper filter prototypes were printed in one piece and electro-polished to improve the surface finish. Aluminium filters were printed in three different orientations to the wiper to investigate the influence on RF performance. All measured results have a good agreement with simulations. Furthermore, an in-depth review and discussion of Additive Manufacturing techniques for producing complex microwave components and strategies to mitigate the drawbacks of AM are given.
Original languageEnglish
Pages (from-to)2027-2037
Number of pages11
JournalIEEE Transactions on Components, Packaging and Manufacturing Technology
Issue number12
Early online date22 Dec 2022
Publication statusPublished - Dec 2022


  • AlSi10Mg
  • Band-pass filters
  • Metals
  • Microwave filters
  • Prototypes
  • Resonator filters
  • Three-dimensional displays
  • Waveguide lasers
  • copper
  • deformed cavity resonator
  • metal 3D printing
  • printing orientation
  • selective laser melting
  • waveguide filter
  • wide stopband
  • wideband bandpass filter

ASJC Scopus subject areas

  • Electronic, Optical and Magnetic Materials
  • Industrial and Manufacturing Engineering
  • Electrical and Electronic Engineering


Dive into the research topics of 'Technological Investigation of Metal 3D Printed Microwave Cavity Filters Based on Different Topologies and Materials'. Together they form a unique fingerprint.

Cite this