Advanced Modeling and Synthesis of Consolidated Additively Manufactured Waveguide Filter Assemblies

High-power, lightweight RF passive components are crucial for satellite communications, managing high powers across broad frequencies. Additive manufacturing (AM), particularly powder-bed fusion, enables the creation of complex, optimized RF designs that traditional methods cannot achieve. Selective laser sintering in AM enhances build time and mechanical support using CAE. Space applications involve costly and unreliable testing conditions, making AI-driven optimization vital. This presentation will outline the workflow from modeling to manufacturing, incorporating RF, thermal, structural, and multipaction analyses. It will also include thermal-structural FEA to predict residual stresses and address parametric and tolerance analyses to ensure compliance with space reliability standards.