A 3-D Printing Filter for High-Power Satellite Applications

A high-performance Ku-band dual-mode filter is proposed for high-power space applications, implemented as an 8th-order structure via 3D-printed AlSi10Mg. The design introduces tangential coupling to excite orthogonal modes within each elliptical cavity and employs smoothly deformed elliptical apertures to connect adjacent resonators. Both structures adopt gentle perturbations composed of arcs rather than sharp edges, effectively disrupting electron multiplication paths and elevating the multipactor threshold. The internal energy distribution is further optimized to suppress field intensity peaks, enhancing power handling capability. Benefiting from well-matched structural design and fabrication process, the filter achieves high performance directly after fabrication, without the need for tuning or coupling screws—thus eliminating contact-induced passive intermodulation (PIM) and fully leveraging the advantages of additive manufacturing. Experimental results demonstrate an insertion loss below 0.4 dB over a 300 MHz bandwidth and a multipactor threshold power exceeding 18 kW. The design achieves simultaneous optimization of electromagnetic performance and multipactor suppression, offering a robust solution for next-generation high-power RF systems.