Design and Manufacturability-Aware Optimization of a 30 GHz Gap Waveguide Bandpass Filter Using Resonant Posts

This paper presents the design and optimization, based on electromagnetic simulation, of a fifth-order bandpass filter centered at 30 GHz, implemented using Gap Waveguide (GWG) technology and pole-type cylindrical resonators, intended for applications in 5G communication systems and high-frequency satellite links. Unlike conventional Chebyshev designs reported in the literature, this study proposes an integrated methodology that combines theoretical synthesis, full-wave electromagnetic modeling, and multivariable optimization, while accounting for manufacturing constraints. The developed method encompasses the electromagnetic characterization of individual resonators, the extraction of cavity–cavity coupling parameters, and the complete implementation of the filter using full-wave electromagnetic simulations. A distinctive aspect of the proposed approach is the explicit incorporation of practical manufacturing effects, such as rounded corners induced by machining processes, alongside analytical and numerical geometric compensation procedures that preserve the device’s electrical response. Furthermore, a combination of gradient-based optimization algorithms and evolutionary strategies is employed to align the electromagnetic response with the target theoretical behavior. The results obtained through electromagnetic simulation indicate that the designed filter achieves return losses exceeding 20 dB and a fractional bandwidth of 4.95%, consistent with the reference Chebyshev response. Finally, the potential extension of the proposed approach to higher frequency bands is discussed conceptually, laying the groundwork for future work that includes experimental validation.