3-D Printed Millimeter Wave Quasi-Optical Lens System for 60 and 100 GHz Applications

This study explores the potential of 3-D printing technologies for the development of free space quasioptical (Q-O) components operating in the millimeter wave frequency regime. Q-O techniques are used to focus millimeter wave signals for power combining applications. This study includes the design process, simulation, fabrication, and testing of dual biconvex shaped lens systems designed for 60 and 100 GHz center frequencies. Test results demonstrate the resultant gain across a 15-wavelength gap between the input and output waveguides in comparison to free space coupling between the two. This study presents a set of unique designs that includes separated lens and alignments structures to facilitate efficient high-resolution lens printing. The 60 GHz system features lenses placed in a self-aligning cavity, while the 100 GHz system requires external alignment due to the small size of the component lenses. The resulting data showed a focusing gain of 18.3 dB at 60 GHz and a gain of 22.1 dB at 100 GHz.