3D-Printed Dielectric Waveguide Without Internal Supports

Solution Overview

Problem

Dielectric foams present challenges in manufacturing waveguides with significant length, requiring an improved method to produce continuous dielectric waveguides without monolithic or sacrificial internal supports.

Innovation Solution

A method of fabricating continuous dielectric waveguides through 3-D printing, using a polymer that transitions from a liquid to a solid state, with incremental advancement and curing, and without monolithic or sacrificial supports, allowing for segments with varying dielectric constants and cross-sectional shapes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If dielectric foams are used to manufacture waveguides, then manufacturing process is simplified, but waveguide length is limited and requires sacrificial internal supports

Engineering Contradiction:

Improvemanufacturing process simplicityVSAvoidwaveguide length

Core Design Contradiction:

Ease of manufactureVSLength of stationary object

Solution Approach 1:

The waveguide is divided into multiple discrete segments that are manufactured separately and then assembled end-to-end to form a continuous long-waveguide. Each segment can be manufactured independently using dielectric foam with simple processes, while the overall waveguide achieves significant length through segmentation and assembly. Internal supports are confined to individual segments rather than spanning the entire length.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

sacrificial internal supports are nested within individual waveguide segments during manufacturing, allowing each segment to be produced with the necessary structural support. After assembly, these nested supports can be removed from each segment independently, enabling long waveguide construction without requiring monolithic supports spanning the entire length.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Stability of the object's composition

If sacrificial internal supports are used in dielectric waveguides, then structural stability is improved, but manufacturing complexity increases due to support removal steps

Engineering Contradiction:

Improvestructural stabilityVSAvoidmanufacturing process complexity

Core Design Contradiction:

Stability of the object's compositionVSDevice complexity

Solution Approach 1:

The waveguide is divided into multiple discrete segments that are manufactured separately and then assembled end-to-end to form a continuous long-waveguide. Each segment can be manufactured independently using dielectric foam with simple processes, while the overall waveguide achieves significant length through segmentation and assembly. Internal supports are confined to individual segments rather than spanning the entire length.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

sacrificial internal supports are nested within individual waveguide segments during manufacturing, allowing each segment to be produced with the necessary structural support. After assembly, these nested supports can be removed from each segment independently, enabling long waveguide construction without requiring monolithic supports spanning the entire length.

Inventive Principle:

Principle #34Discarding and recovering

3Stability of the object's composition

If continuous dielectric waveguides are manufactured without segmentation, then structural continuity is improved, but manufacturing difficulty increases for significant lengths

Engineering Contradiction:

Improvestructural continuityVSAvoidmanufacturing ease

Core Design Contradiction:

Stability of the object's compositionVSEase of manufacture

Solution Approach 1:

The waveguide is divided into multiple discrete segments that are manufactured separately and then assembled end-to-end to form a continuous long-waveguide. Each segment can be manufactured independently using dielectric foam with simple processes, while the overall waveguide achieves significant length through segmentation and assembly. Internal supports are confined to individual segments rather than spanning the entire length.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Multiple individually manufactured waveguide segments are joined together through coupling structures to form a continuous waveguide assembly. The coupling mechanisms merge the segments into a unified structure that maintains structural continuity and electromagnetic wave propagation while allowing each segment to be manufactured separately with simplified processes.

Inventive Principle:

Principle #5Merging (Combining)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

Enables the production of continuous dielectric waveguides with lengths of at least three meters, featuring lattice structures and varying thicknesses, without seams or additional manufacturing steps for support removal, enhancing manufacturing efficiency and flexibility.

Implementation Method 1

curing a polymer in a reservoir from a first state to a second state

Methodology Applied

Scientific EffectCuring: Photopolymerisation

Data Source

PatentUS20260011904A1Additive manufactured waveguide

Publication Date: 2026.01.08 SAMTEC INC

AI summary

A cable can include a first end and a second end. The cable can be adapted to transmit an electrical signal or light from the first end to the second end. The cable can be a non-extruded dielectric. The cable can be a waveguide. The cable can be manufactured by three-dimensional printing. The cable can have any desired length. The cable can be manufactured by sequentially printing any number of segments.