Selective Laser Melting of 316L WR-90 Waveguide Horn Antennas: Experimental RF Characterization and Quantitative Performance Analysis

This paper presents the fabrication and experimental characterization of a 316L stainless-steel WR-90 waveguide horn antenna manufactured using selective laser melting (SLM) and operating across the X-band (8.2–12.4 GHz). The antenna is designed based on standard WR-90 waveguide theory and incorporates a coaxial-to-waveguide transition and a flared radiating aperture to achieve stable aperture-based radiation. Full-wave electromagnetic simulations are performed to establish baseline impedance, radiation pattern, and gain performance prior to fabrication. The SLM-fabricated prototype is evaluated through reflection coefficient, radiation pattern, and realized gain measurements conducted in an anechoic chamber. Measured results confirm stable impedance matching across the entire band, with |S11| below −10 dB and a minimum of −22.34 dB near 10.1 GHz. The radiation patterns closely follow simulation predictions, with half-power beamwidth deviations below 4%. The realized gain increases from 11.2 dBi to 15.8 dBi across the band, with simulation–measurement deviation decreasing to within 0.5 dB above 10 GHz. Rather than focusing on antenna design novelty, this work employs a standardized WR-90 horn antenna as a benchmark structure to isolate fabrication-induced effects. A quantitative performance analysis is introduced by converting the gain deviation into an equivalent efficiency reduction, providing a practical framework for evaluating fabrication-induced electromagnetic degradation in SLM-fabricated waveguide components.