Plastic injection micromachining of millimeter and sub-millimeter rectangular waveguide filters

In this paper, plastic microinjection molded WR-3 rectangular metalized waveguides are demonstrated. The process is simple to implement and allows fabrication of complex 3D structures. Different types of waveguide filters are fabricated using this process and measured results are reported. Simulation results show that filters with good performance in the millimeter and sub-millimeter wave range can be attained using the proposed process. Preliminary measured results on fabricated filters are presented.