Monolithic RF Waveguide With In-Place Support Bridges
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Solution Overview
Problem
Large format waveguides manufactured using additive manufacturing face challenges such as manufacturing defects, surface roughness, and stitching errors due to misalignment of multiple print sources, leading to increased costs, complexity, and reduced reliability.
Innovation Solution
A monolithic waveguide design with integrated support bridges that remain in place during operation, eliminating the need for post-manufacturing assembly and removal of internal support structures, thereby reducing defects and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional manufacturing processes with multiple parts and assembly are used, then manufacturing flexibility is improved, but device complexity and assembly time increase
Solution Approach 1:
The patent combines multiple waveguide components (waveguide body, support structures, filters, and bridges) into a single monolithic structure manufactured by additive manufacturing. This eliminates the need for separate assembly operations, reducing assembly complexity while maintaining manufacturing flexibility through digital design and production.
Solution Approach 2:
The additively manufactured waveguide structure serves multiple functions simultaneously: it provides the waveguide body, internal support structures, filtering elements, and bridging components all in one monolithic part. This multi-functionality reduces the number of separate components and assembly steps required.
2Manufacturing precision
If internal support structures are used during additive manufacturing, then manufacturing precision is improved, but device complexity and post-processing time increase
Solution Approach 1:
The patent extracts the support structure function from temporary manufacturing aids and integrates it permanently into the waveguide body as functional bridging structures. These bridges remain as part of the final product, eliminating the need for post-processing removal while maintaining surface stability during manufacturing.
Solution Approach 2:
The support structures are built into the waveguide body during the additive manufacturing process itself, rather than being added or removed afterward. This preliminary integration of support functions eliminates subsequent material removal operations and reduces post-processing complexity.
3Productivity
If multiple print sources are used in large format additive manufacturing, then productivity is improved, but manufacturing precision deteriorates due to stitching errors
Solution Approach 1:
The patent combines the outputs of multiple print sources into a single monolithic waveguide structure. By designing the waveguide as one integrated part manufactured simultaneously by multiple print sources, stitching errors are minimized as the structure is built as a unified whole rather than assembled from separately printed components.
Data Source
AI summary
A radio frequency (RF) waveguide comprising a channel, a filter, and a support bridge. The channel can comprise an outer wall defining an inner cavity configured to propagate electromagnetic waves. The filter can be disposed in the inner cavity of the channel and can comprise a perimeter edge and an aperture. The support bridge can comprise a first interface connected to an inner surface of the outer wall at a first location, and a second interface connected to the filter at a position between the perimeter edge and the aperture of the filter to support the filter within the channel. The support bridge can remain in place as connected to the filter, and the filter and waveguide can operate without interference from the support bridge, meaning that the waveguide meets all performance specifications and functions as intended for a particular application even with the support bridge left in place.