Micromachined plastic W-band bandpass filters

Results are presented for micromachined plastic waveguide bandpass iris filters for W-band applications using a cost-effective polymer micro hot embossing process in conjunction with metallic electroplating and sealing techniques. The prototype filter has an 8-μm thick electroplated gold layer on a polymeric WR-10 waveguide with a 5-cavity Chebyschev-type design. Measurement results show center frequency of 96.77 GHz with a bandwidth of 3.15%, a loaded quality factor 31.73 and an unloaded quality factor for a single cavity resonator is 1210.6, respectively. A minimum insertion loss of −1.22 dB and return loss of better than −9.3 dB have been measured over the entire passband.