Method for Producing High-Frequency Functional Structures

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This invention describes a method for manufacturing high-frequency functional structures (such as waveguides, antennas, filters, resonators, and couplers) by applying an electrically conductive layer to a form-determining base body. The conductive coating is achieved by wetting the non-conductive core (often made via 3D printing or injection molding from plastic or ceramic) with a dispersion containing micro- or nanoparticles of conductive metals (e.g., silver, copper, gold, aluminum). After application, the coating is solidified, such as by sintering or other thermal/UV treatments.

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• Production of waveguides for aerospace and satellite communications.
• Manufacturing of antennas (e.g., horn or helix antennas) for radar, wireless communication, or sensing systems.
• Creation of RF and microwave filters, resonators, or passive components in telecommunications.
• Production of custom or complex-shaped high-frequency components via additive manufacturing (3D printing).
• Manufacture of cost-effective RF components for automotive radar systems or IoT devices.

BenefitsContent extracted from patent full text and abstract with AI.

• Enables production of complex-shaped high-frequency components at a lower cost compared to traditional metal machining.
• Improves surface smoothness and electrical performance of RF components by reducing roughness compared to chemical metallization.
• Supports use of lightweight, inexpensive materials (plastics, ceramics) with precise conductive coatings.
• Allows flexibility in component design with fewer geometric constraints than electroplating or galvanic methods.
• Reduces manufacturing time and enables rapid prototyping of customized components.
• Compatible with modern additive manufacturing for streamlined workflow from design to finished RF device.

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Inventors & Applicants

Patent Abstract

The invention relates to a method for manufacturing high-frequency functional structures, said method comprising the following steps: providing a base body that determines the shape of the functional structure; and applying an electrically conductive layer to the shape-determining base body by wetting the base body with a dispersion containing microparticles and/or nanoparticles.