Prototyping a broadband waveguide circulator centered at 2.45 GHz using 3D printing

Abstract

The ferrite waveguide circulator available on the market nowadays has a rigid housing made up of metal and connected with several mechanical joints. The parts are assembled by molding, brazing, metallization, silver, or conventional soldering. These traditional techniques usually increase the production cost of one unit. The testing of these devices and the corresponding fine-tuning for the desired frequency and bandwidth lead to further increase of the cost and time. Hence, we propose to use the 3D printing technology to prototype the ferrite waveguide circulator. The metal circulators commonly used in industries are generally more expensive. Therefore, the experimental prototype of a WR340 ferrite waveguide circulator can be built using a cost-effective 3D printing technology for validating the design and comparing with the simulation results. The said circulator has a simple structure; hence by using the Lego method, the unit can be quickly produced and assembled. This paper presents how to 3D print a circulator housing, which is then metal coated. the ferrite discs are then fixed at the chamfer center enclosed by the magnets on both sides to complete the magnetic circuit. The circulator developed by this additive manufacturing is expected to have a bandwidth of 150 MHZ or higher with a transmission of 93% operated at 2.45GHz frequency.