3D-Printed Dual-Mode Invar Channel Filters for Ku-Band Satellite Payloads
This paper presents an end-to-end process of realization of channel filters for output multiplexers (OMUX) in satellite payloads. The filters are designed at 11.609 GHz using dual-mode cylindrical resonators operating at TE113 degenerate modes. Two filters were fabricated from Invar alloy, making us...
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| Format: | Article |
| Language: | English |
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IEEE
2025-01-01
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| Series: | IEEE Journal of Microwaves |
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| Online Access: | https://ieeexplore.ieee.org/document/10799161/ |
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| author | Talal Skaik Emelia Hayward EL-Moez A. Abd Mohamed Moataz M. Attallah Lu Qian Cesar Miquel Espana Paul Booth Yi Wang |
| author_facet | Talal Skaik Emelia Hayward EL-Moez A. Abd Mohamed Moataz M. Attallah Lu Qian Cesar Miquel Espana Paul Booth Yi Wang |
| author_sort | Talal Skaik |
| collection | DOAJ |
| description | This paper presents an end-to-end process of realization of channel filters for output multiplexers (OMUX) in satellite payloads. The filters are designed at 11.609 GHz using dual-mode cylindrical resonators operating at TE113 degenerate modes. Two filters were fabricated from Invar alloy, making use of its low coefficient of thermal expansions (CTE) of 1-2 ppm/K, using powder bed fusion with laser beam (PBF-LB) process. The first filter, as a reference design for comparison purpose, is comprised of four pieces assembled using screws, while the second filter was printed monolithically as one part. The paper presents various design solutions to significantly reducing the filter weight. This includes hollowed flanges and reduced wall thickness, around 0.5 mm, and using waffle structure with reinforcing ribs. The monolithic printed filter offers a weight reduction of 65% compared to the four-piece filter. Post processing techniques including vibratory grinding polishing and silver plating were applied. Both filters were tuned using tuning screws and the measurements are in good agreement with the simulated results. The RF-thermal measurements showed negligible frequency shift confirming the temperature stability for high-power operation in satellite environment. |
| format | Article |
| id | doaj-art-55a9f0f7352140f1bc36af211266974a |
| institution | Kabale University |
| issn | 2692-8388 |
| language | English |
| publishDate | 2025-01-01 |
| publisher | IEEE |
| record_format | Article |
| series | IEEE Journal of Microwaves |
| spelling | doaj-art-55a9f0f7352140f1bc36af211266974a2025-01-15T00:04:03ZengIEEEIEEE Journal of Microwaves2692-83882025-01-015117017910.1109/JMW.2024.3509956107991613D-Printed Dual-Mode Invar Channel Filters for Ku-Band Satellite PayloadsTalal Skaik0https://orcid.org/0000-0002-9202-7934Emelia Hayward1EL-Moez A. Abd Mohamed2Moataz M. Attallah3https://orcid.org/0000-0002-7074-9522Lu Qian4Cesar Miquel Espana5https://orcid.org/0009-0007-6460-2966Paul Booth6https://orcid.org/0000-0002-3296-888XYi Wang7https://orcid.org/0000-0002-8726-402XSchool of Engineering, University of Birmingham, Birmingham, U.K.School of Engineering, University of Birmingham, Birmingham, U.K.School of Metallurgy and Materials, University of Birmingham, Birmingham, U.K.School of Metallurgy and Materials, University of Birmingham, Birmingham, U.K.School of Engineering, University of Birmingham, Birmingham, U.K.European Space Agency, Noordwijk, AZ, The NetherlandsAirbus Defense and Space Ltd., Stevenage, U.K.School of Engineering, University of Birmingham, Birmingham, U.K.This paper presents an end-to-end process of realization of channel filters for output multiplexers (OMUX) in satellite payloads. The filters are designed at 11.609 GHz using dual-mode cylindrical resonators operating at TE113 degenerate modes. Two filters were fabricated from Invar alloy, making use of its low coefficient of thermal expansions (CTE) of 1-2 ppm/K, using powder bed fusion with laser beam (PBF-LB) process. The first filter, as a reference design for comparison purpose, is comprised of four pieces assembled using screws, while the second filter was printed monolithically as one part. The paper presents various design solutions to significantly reducing the filter weight. This includes hollowed flanges and reduced wall thickness, around 0.5 mm, and using waffle structure with reinforcing ribs. The monolithic printed filter offers a weight reduction of 65% compared to the four-piece filter. Post processing techniques including vibratory grinding polishing and silver plating were applied. Both filters were tuned using tuning screws and the measurements are in good agreement with the simulated results. The RF-thermal measurements showed negligible frequency shift confirming the temperature stability for high-power operation in satellite environment.https://ieeexplore.ieee.org/document/10799161/3D printingadditive manufacturingcylindrical filtersatellite payloadwaveguide |
| spellingShingle | Talal Skaik Emelia Hayward EL-Moez A. Abd Mohamed Moataz M. Attallah Lu Qian Cesar Miquel Espana Paul Booth Yi Wang 3D-Printed Dual-Mode Invar Channel Filters for Ku-Band Satellite Payloads IEEE Journal of Microwaves 3D printing additive manufacturing cylindrical filter satellite payload waveguide |
| title | 3D-Printed Dual-Mode Invar Channel Filters for Ku-Band Satellite Payloads |
| title_full | 3D-Printed Dual-Mode Invar Channel Filters for Ku-Band Satellite Payloads |
| title_fullStr | 3D-Printed Dual-Mode Invar Channel Filters for Ku-Band Satellite Payloads |
| title_full_unstemmed | 3D-Printed Dual-Mode Invar Channel Filters for Ku-Band Satellite Payloads |
| title_short | 3D-Printed Dual-Mode Invar Channel Filters for Ku-Band Satellite Payloads |
| title_sort | 3d printed dual mode invar channel filters for ku band satellite payloads |
| topic | 3D printing additive manufacturing cylindrical filter satellite payload waveguide |
| url | https://ieeexplore.ieee.org/document/10799161/ |
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