This thesis addresses itself to the solution of a number of problems which arise in the development of Radio Frequency filters, particularly those involving coupled transmission lines as resonant elements. The text is divided into a number of sections dealing with individual topics. After a brief description of Darlington filter design principles, there is an account of the pivotal role of quarter wave sections and their vital part in the realisation of high frequency filters. This is followed by the development of new material relating to equivalent circuits of physical lines in terms of quarter wave sections, and its application to improvements in the design of wide-band filters. There follows an account of a new procedure for calculating the dimensions of comb-line and inter-digital filters. This section includes a new proposal for the inversion of Getsinger's procedure to permit the calculation of rectangular rod dimensions and spacings from given electrical data. There is also an algorithm for use with round rods which circumvents the tedious manual interpolation procedure devised by Cristal. There follows an investigation of and a proposed solution to a long-known but unexplained discrepancy existing between the calculated and measured pass-band width of the class of comb-line filters. With the new procedure the discrepancy reported previously to be of the order of 10% is eliminated. Finally, experimental evidence is adduced to verify the algorithms outlined in the preceding chapters.

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.