Method for Producing High-Frequency Functional Structures and High-Frequency Functional Structure

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This invention describes a new manufacturing process for high-frequency functional structures, such as waveguides and antenna components. The process uses an additive manufacturing step (like 3D printing) to create a highly pure model of the desired structure, embeds this model in a mold material, removes the model to create a casting mold, and then fills the mold with molten metal. The method enables the production of complex, high-precision, and smooth-surfaced high-frequency components using purer materials, overcoming limitations of previous technologies.

Use CasesContent extracted from patent full text and abstract with AI.

• Production of high-frequency waveguides for telecommunications and radar systems.
• Manufacture of antennas with complex internal geometries, including horn and slotted waveguide antennas.
• Development of microwave filters, resonators, and couplers with high geometric precision.
• Miniaturized and complex passive high-frequency components for aerospace, defense, and satellite communications.
• Creation of monolithic metal components with superior surface smoothness for high-power radio-frequency (RF) applications.

BenefitsContent extracted from patent full text and abstract with AI.

• Allows manufacturing of highly complex and precise RF structures that traditional machining or metal 3D printing cannot easily achieve.
• Enables the use of a wider range of metals and alloys, including those unsuitable for metal additive manufacturing.
• Improves surface smoothness, reducing RF losses and enhancing electromagnetic performance.
• Results in components with high purity, mechanical strength, and thermal stability, critical for high-power and high-frequency applications.
• Facilitates miniaturization of components without the complexity and cost of conventional processes.
• Improved process cleanliness, with minimal residue in molds due to the high purity of template materials.
• Reduces limitations associated with support structures in additive manufacturing, as temporary supports can be dissolved and removed efficiently.

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Patent Abstract

The present invention relates to a method for producing high-frequency functional structures comprising the following steps: - producing an image of the functional structure; - forming the image into a moulding material; - removing the image from the moulding material, with the result that a casting mould is produced; - introducing a molten mass into the casting mould; - demoulding of the solidified molten mass, wherein over 90%, preferably over 95%, in particular over 99% of the mass of the image consists of a pure material.