Metalized Stereolithography 3D-Printed Rectangular Waveguide Components for Terahertz Radiation

Rectangular waveguides, serving as a standardized versatile platform for manipulating terahertz radiation within controlled environments, have been extensively employed across a broad range of terahertz systems. However, conventional fabrication methods encounter significant challenges in realizing such submillimeter-scale structures within a monolithic integration, particularly when subwavelength features or intricate geometries are incorporated for advanced functionalities. In this work, we propose a fabrication route integrating stereolithography 3D printing and electroless plating, and demonstrate its broad applicability, intrinsic benefits and limitations through the realization of various high-performance D-band terahertz rectangular waveguides and antennas. The resulting rectangular waveguides achieve an insertion loss below 0.3 dB and a return loss above 15 dB across the D-band, while remaining stable across extreme temperatures (−50 °C to 150 °C) and offering a weight reduction of over 60%. A monolithically fabricated smooth-walled conical horn antenna exhibits beam-shaping characteristics that closely align with theoretical expectations. Attempts on corrugated horn antennas in conventional design reveal degraded performance, primarily arising from the inherent staircase effect associated with 3D printing. A novel design featuring obliquely oriented corrugations is developed, effectively mitigating uncontrolled deformation in periodic subwavelength features. Compared with the classical corrugated design (θ = 90°), the proposed obliquely oriented corrugations (θ = 30°) improve the agreement between experimental and theoretical radiation patterns, reducing the gain deviation from 1.45 dB to less than 0.5 Db—a quantitative improvement of over 60% in pattern fidelity. We believe that this fabrication route together with the process-adaptive design paradigm establishes a robust technical foundation for realizing high-performance, lightweight, and design-flexible terahertz waveguide components and holds significant promise for advancing the development of next-generation integrated terahertz systems.