Additive Manufacture of Custom Radiofrequency Connectors

We present the design and characterization of fully additively manufactured (AM) SubMiniature version A (SMA) connectors for use up to 18 GHz. Three-dimensional printed connectors can be directly integrated into the radio-frequency (RF) circuit without post-process bonding and can be fabricated into unusual shapes. The flexibility this affords in the manufacturing process offers significant advantages, especially for applications that need to meet strict size and volume constraints. To that end, we describe modifications to the traditional SMA design that better enable AM fabrication. A variety of different connector geometries were printed and fully characterized both electromagnetically and mechanically. Experimental measurements up to 18 GHz demonstrated good RF performance with low insertion losses (< 0.5 dB). Mechanical testing showed that the printed connectors could withstand up to 4.5 kg of direct force for extended periods of time without damage to the printed threads or other connector parts. Additionally, the printed connectors demonstrated good RF performance after repeated use.