Robust design methods and technologies for millimeter-wave components

In this thesis, a novel gap waveguide topology is presented alongside an innovative manufacturing approach, complemented by a variety of design methods and topologies for gap waveguide low-pass filters (LPFs) and bandpass filters (BPFs). Moreover, a new design method for filtering antennas is proposed. The primary objective behind all these designs is to develop topologies that can effectively withstand manufacturing tolerances. To begin with, a novel gap waveguide topology is introduced and compared with existing designs from the literature, offering a promising alternative for future applications. Moreover, a cutting-edge manufacturing technique is proposed, leveraging selective laser melting (SLM) and subsequent computer numerical control (CNC) milling to address common challenges associated with selective laser melting, including surface roughness and manufacturing imperfections. In the field of microwave filters, a gap waveguide low-pass filter is presented for the first time. This approach simplifies the design process, employing closed-form expressions and rapidly performing calculations using simulation software. Additionally, several bandpass filters utilizing higher-order modes are introduced, featuring diverse topologies, including inline and stacked configurations. Notably, the innovation in their design extends to create bandpass filters with reduced sensitivity to manufacturing tolerances. This development is particularly pertinent for Q/V/W-band satellite payloads, where it significantly enhances fabrication yields compared to traditional filter designs. Lastly, this Thesis presents an innovative and comprehensive design methodology, encompassing the integration of microwave filters and antennas, known as a filtering antenna. The concept of a filtering antenna offers a multifaceted solution to address the evolving demands of modern communication systems. It combines the functionality of microwave filters with antennas, essential for signal transmission and reception. This integration not only simplifies the system architecture but also brings forth a range of benefits in terms of performance, space utilization, and overall system efficiency.