Advanced Design and Fabrication of Microwave Components Based on Shape Optimization and 3D Ceramic Stereolithography Process

The design of advanced components for space and terrestrial telecommunication systems requires both sophisticated design methodologies and manufacturing technologies for improving current component characteristics. In particular, optimizing the shape and the size of a component is a problem of primary importance for microwave engineers. Moreover, for designing RF and microwave components or antennas, the use of ceramic materials is preferable in order to satisfy both electrical and dimensional constraints. The main objective of this chapter is to demonstrate that it is possible to jointly improve the design and fabrication procedures of ceramic based advanced RF components. In this context, a ceramic 3D stereolithography based rapid prototyping technique is applied for fabricating 3D ceramic structures. As presented next, theoretical and experimental approaches are complementary and innovative components with excellent electrical performances have been designed, manufactured and characterized. Then the contribution demonstrates how an original CAD design approach based on shape optimization methods can be applied for improving electrical performance and integration of microwave and millimeter-wave devices.