3D Printed Microwave Solutions for

A 3D printed antenna is built in four stages: EM design and simulation, monolithic polymer printing, metallization, and RF validation. The antenna body prints as a single part on a high-resolution printer, then gets fully metallized in our own coating line. Because the internal waveguide features are printed rather than milled into two halves and joined, there is no split plane and no alignment tolerance to manage. Every part is validated with beam patterns and S-parameters before it ships.

• 1 part Monolithic body
• 0 Split planes

Design & production

Yes! A custom antenna project can start from either. If you send an electrical specification, our team designs the geometry and runs the EM simulation before production is initiated. If you already have a finished CAD model, we apply DFM for the printing and metallization process and take it into production directly.

Design & production

Standard waveguide sizes run from WR112 down to WR3, which covers 3 to 110 GHz; horns, feed networks and slotted arrays are typically built between 18 and 110 GHz. Custom geometry is reviewed up to 300 GHz. The interface is a WR or UG flange, or a custom bolt pattern, and the usable band is fixed at design review from the geometry, the coating stack and the RF acceptance target.

• WR112 – WR3 Waveguide sizes
• 3 – 110 GHz Standard range
• 300 GHz Custom, on review

Sizes & RF performance

A metallized polymer antenna is around six times lighter than the machined metal equivalent and reaches first hardware roughly five times faster, because there is no tooling and no split-block assembly step. RF performance stays in the same envelope: below 5 dB/m attenuation at 75 GHz, verified up to 300 GHz.

• 6x lighter vs machined metal
• 5x faster To first hardware
• < 5 dB/m at 75 GHz

Sizes & RF performance

Yes. The metallization is automotive and soldering qualified, and robustness is tested against automotive standards. We also run environmental tests and CT scans in-house, so structural integrity is verified rather than assumed.

Robustness & validation

Both. There is no tooling involved, so the cost per part does not depend on a mould being amortised. We handle quantities from a single prototype up to more than 100,000 units, and every unit gets end-of-line testing.

• 1 – 100,000+ Quantity range
• No tooling Cost basis

Project & delivery

Between 3 and 12 weeks, depending on how much design work is needed. Manufacturing from an existing CAD model sits at the short end of that range, around 3 to 6 weeks. A full design cycle from your specification takes 4 to 12 weeks depending on the requirements and the closed-loop design iterations we must do on our side. Send us the specification and we will confirm a firm date with the quote.

• 3 – 6 wk From your CAD
• 4 – 12 wk From specification

Project & delivery

Everything happens at our own site in Erlangen, Germany: design, printing, metallization and measurement. Nothing is subcontracted out between those stages, which is also why we can keep full traceability on every shipment.

• Erlangen Single site, Germany

Project & delivery