Multiphysics Analysis for Design-Assembly Consolidation with Additively Manufactured Waveguide Structures

High power light weight RF passive components are critical for satellite communications payloads and are required to handle increasingly larger peak/average powers. Powder-bed fusion metal Additive Manufacturing (AM) process has matured as a breakthrough technology for the development of arbitrary shape RF and microwave components where conventional machining can be complex or impossible to use. Leveraging the use of Artificial Intelligence (AI) optimization techniques in the design process of RF components is impactful. The presented work demonstrates the use of physics-based simulation technologies from modelling/synthesize to manufacturing process of an optimized band pass filter that can be safely launched to space for satellite communication.