Additive manufacturing (AM) is an attractive way to shorten development time, reduce product weight and allow the manufacturing of more complex products than by conventional manufacturing processes. The problem arises when the previous traditional manufacturing requirements need to be fulfilled by AM as well as the volume production capability. This investigation is done together with Ericsson to evaluate the possibilities of the different AM technologies, post-processing methods and silver coating processes to guarantee the specifications of radiofrequency (RF) filters. Here, minimal RF signal insertion losses are targeted. Since insertion losses are dependent on surface roughness, surface smoothness is sought as well. Ericsson simulation software uses correction factors to account for surface roughness, however there are some inconsistencies between the simulated and actual surface roughness that is allowed in the parts. In AM parts, surface roughness is not easy to control since it depends on parameters related to feedstock, process and machine properties. Commonly, most AM components do not comply with requirements of lower surface roughness values. Therefore, parts need to be smoothened before silver plated; this step is necessary to ensure the electrical conductivity in this specific application. These finishing processes add costs to the final product and increase time to market. Firstly, a comprehensive study was carried out to better understand the landscape of AM technologies, postprocessing and silver coating methods. Secondly, the different processes are assessed with the help of selection matrices, considering the products requirements. The components to print are two RF filters with different shapes and dimensions but similar requirements. The CAD design is modified depending on each AM process and directly affects the results. Afterwards, the design of an experimental plan is carried out; the number of samples of each part comparing AM technologies, feedstock, different suppliers (3D printing and post-processing) is obtained. Due to budget and time restrictions, the parts were printed using Multi Jet Fusion and Selective Laser Melting processes. After printing, tolerances and surface roughness were measured. This thesis results in the selection of suitable AM technologies and post-processing methods for RF filters. For MJF printed cavities at 0˚, 30˚ and 90˚ orientation, the best results for this application are obtained at 30˚ providing a good balance between sharp detail and smooth surfaces. In the case of SLM, waveguides are printed at 0˚ and 30˚. 30˚ waveguides present lower surface roughness values than the 0˚ ones as inner support material is needed at 0˚ orientation. SLM cavities were printed at 30˚ in seek of asymmetry between faces, resulting in higher surface roughness in the downfacing face.

Polyamides are commonly used in additive manufacturing for final part production, but the material performance can be affected by environmental conditions. The purpose of this project was to evaluate the effects of moisture and temperature on 3D printed polyamides and how structural optimization can benefit from condition-specific data. Conditioned and unconditioned specimens were tensile tested in regions of -20 °C, 23 °C and 60 °C. Two techniques were evaluated; multi jet fusion and selective laser sintering, and mainly two polyamides; polyamide 11 and polyamide 12. Simulations with the obtained data were performed as well as conceptual structural optimization with the intent of optimizing for the intended end-use environment. Infrared thermography provided specimen temperatures as well as temperature and strain relations present during testing. The stress-strain curves obtained showed generally decreasing stiffness and strength with increasing moisture and temperature, albeit moisture in certain cases increased the tensile modulus at freezing temperatures. Temperature affected stiffness and strength more so than moisture. Polyamide 11 absorbed moisture at a higher rate than polyamide 12. The mechanical performance of laser-sintered polyamide 12 was superior, while laser-sintered polyamide 11 showed great elongation before breakage. Further investigation of polymer crystallinity could explain the behaviour of the 3D printed polyamides.

In recent years, multi-jet fusion technology became more popular as it has unlimited potential. Thanks to this technology, it became possible to produce products with complex geometries.This gives a massive advantage compared to the conventional manufacturing process, as by utilising 3D printers, the costs and environmental impact are reduced exponentially with regards to the fact that this is a new technology. Product quality is one of the most important factors when it comes to product manufacturing for a company to stay competitive in the market. This study was conducted in FABLAB at Halmstad University. The research focuses on different aspects of the fabricated test artefacts, such as surface roughness, tensile strength and dimensional deviation. How different printing parameters can affect the printing quality of the printed parts is then analysed. The result is then compared with designed CAD model. During this study, some experiments were conducted by printing test samples at different build orientations to define the printing quality. Measurement is conducted on the different test artefacts and quantified. The effect from build orientation on surface roughness, tensile strength and dimension accuracy were studied during this thesis. The test samples were measured by using appropriate measuring equipment that was available at Halmstad University. From the test results, it becomes clear that the build orientation directly impacts the printing quality of the printed test samples from the HP multi-jet fusion 3D printer