Optimizing Electromagnetic Performances of L-PBF Aluminium Waveguides through Surface Roughness Control

Poncelet, Olivier;Humbeeck, Victor;Gaillard, Quentin;Verlinden, Arthur;Simar, Aude;et.al.
(2026) Metal AMS 2026 — Location: Setim, Senlis, France (25.March.2026)

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Abstract
In this study, AlSi10Mg and Al6061-Zr rectangular waveguides, operating in the 24–40 GHz frequency range (K-band/WR24), were fabricated using various L-PBF process parameters and scanning strategies aimed at controlling the surface roughness of the inner walls, either globally or selectively. This approach allowed to assess the influence of roughness distribution on waveguide performance. The results indicate that electromagnetic losses remained relatively low across all tested configurations. This suggests that LPBF-fabricated waveguides can achieve acceptable performance in certain high-frequency bands, even without extensive post-processing.
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Poncelet, O., Humbeeck, V., Gaillard, Q., Verlinden, A., & Roy, G. (2026). Optimizing Electromagnetic Performances of L-PBF Aluminium Waveguides through Surface Roughness Control. https://hdl.handle.net/2078.5/275482