Rapid 3D prototyping and fabricating of slow-wave structures, including electromagnetic meta-material structures, for millimeter-wavelength and terahertz-frequency high-power vacuum electronic devices

Abstract

A method for fabricating slow-wave structures, including electromagnetic meta-material structures, for high-power slow-wave vacuum electronic devices operating in millimeter-wavelength (30 GHz-300 GHz) and terahertz-frequency (300 GHz and beyond) bands of electromagnetic spectrum. The method includes: loading a digital three dimensional model of a slow-wave structure in a memory of a 3D printer, the loaded digital three dimensional model having data therein representative of the slow-wave structure to be fabricated by the 3D printer; loading metal powder material into the 3D printer; and operating the 3D printer to melt the metal powder material in accordance with the loaded three dimensional model of the slow-wave structure and then to solidify the melted layer of the metal powder material to fabricate the slow-wave structure layer by layer.

Claims

1. A method, comprising: 3D printing a slow-wave structure, the slow wave structure comprising: a unitary structure comprising: an outer wall extending longitudinally along a z-axis, the z-axis being perpendicular to an x-y plane, the outer wall enclosing a central region; and a plurality of sections, the sections being angularly spaced one from another around the central region, each one of the sections comprising: a periodic array of elements of electrically conductive material projecting radially inwardly from the outer wall in the x-y plane and terminating in the central region, the elements in each one of the sections being angularly spaced one from another in both the x-y plane and along columns disposed along parallel to the z-axis; wherein each one of the sections comprises: a plurality of rows of the elements, the elements in each one of the rows being angularly spaced one from another, and a plurality of columns of the elements, the elements in each one of the columns being angularly spaced one from another; and wherein the angularly spacing between the sections is greater than the angularly spacing between the elements in each one of the columns and each one of the rows.

2. A method comprising: 3D printing a slow-wave structure, the slow-wave structure comprising: a unitary structure comprising: an outer wall extending longitudinally along a z-axis, the z-axis being perpendicular to an x-y plane, the outer wall enclosing a central region; and a plurality of sections, the sections being angularly spaced one from another around the central region, each one of the sections comprising: a periodic array of rows and columns of angularly spaced rod-like elements disposed in a corresponding one of a angularly spaced plurality of parallel X-Y planes, the plurality of X-Y planes being vertically stacked along a Z-axis; distal ends of the elements being equally angularly spaced one from another in each of the rows thereof and the X-Y planes being equally angularly spaced one from another along a Z-axis, the Z axis being perpendicular to the X-Y planes, the rod-like elements projecting radially inwardly from the outer wall and terminating in the central region; wherein each one of the sections comprises: a plurality of rows of the rod-like elements, the rod-like elements in each one of the rows being angularly spaced one from another; and a plurality of columns of the rod-like elements, the rod-like elements in each one of the columns being angularly spaced one from another; and wherein the spacing between the sections is greater than the spacing between the rod-like elements in each one of the columns and each one of the rows.

3. A method comprising 3D printing a slow-wave structure comprising a periodic array of elements of electrically conductive material spaced one from another in both a plane and along a column disposed along a direction perpendicular to such plane; wherein the elements of electrically conductive material are disposed in the plane project towards an interior region of the slow-wave structure; wherein the slow-wave structure is a cylindrical structure and wherein the elements of electrically conductive material project along radial lines of the cylindrical structure and comprising a periodic array of rows and columns of each one row of a plurality of spaced rod-like elements disposed in a corresponding one of a spaced plurality of parallel X-Y planes, the plurality of X-Y planes being vertically stacked along a Z-axis; distal ends of the elements being equally spaced one from another in each of the rows thereof and the X-Y planes being equally spaced one from another along a Z-axis, the Z-axis being perpendicular to the X-Y planes, wherein the thickness of the elements is 0/M where M is between 3.5 and 4.5 where 0 is the operating wavelength of the slow-wave structure, and wherein the slow-wave structure operates at frequencies corresponding to millimeter-wavelength and terahertz-frequency bands of the electromagnetic spectrum.

Description

DESCRIPTION OF DRAWINGS

(1) FIGS. 1A and 1B are, respectively, a top view and an isometric view of a slow-wave structure according to the PRIOR ART;

(2) FIGS. 2A and 2B are, respectively, a side view and a cross-sectional, isometric, view showing an inner portion of a slow-wave structure according to the disclosure; this particular anode slow-wave structure comprising radially directed rod-like elements grouped in sections periodically spaced in azimuthal direction and dimensioned for operation at frequencies corresponding to millimeter-wavelength and terahertz-frequency bands of electromagnetic spectrum;

(3) FIG. 2C is an isometric view and FIG. 2D is a cross sectional view looking towards a bark-wall of a portion of the slow-wave structure of FIG. 2B along a plane parallel to the vertical axis passing through a portion of a column of rod-like elements used in such slow-wave structure;

(4) FIG. 2D is a cross sectional view of a portion of the slow-wave structure of FIGS. 2A, 2B and 2C;

(5) FIG. 3 is a flow chart of a process used to fabricate the anode slow-wave structure of FIGS. 2A-2D according to the disclosure;

(6) FIGS. 4A and 4B illustrate operation of a 3D printer used to fabricate the anode slow-wave structure of FIGS. 2A and 2B according to the flow chart of FIG. 4;

(7) FIGS. 5A-5F illustrate the layer by layer formation during operation of the 3D printer of FIGS. 4A and 4B to fabricate the anode slow-wave structure of FIGS. 2A-2C according to the flow chart of FIG. 4; and

(8) FIG. 6 is a cross-section view of an exemplary one rod-like element of electrically conductive material used in the anode slow wave structure of FIGS. 2A-2D after depositing, melting and solidifying of portions of layers of the metal powder material used in the process to form the rod-like element.

(9) Like reference symbols in the various drawings indicate like elements.

DETAILED DESCRIPTION

(10) Referring now to FIGS. 2A, 2B, 2C and 2D, an electromagnetic meta-material structure, here for example, an anode slow-wave structure 12 used for generation or amplification of electromagnetic waves growing inside or passing through the anode slow-wave structure 12 is shown, disposed along the longitudinal, Z, axis and dimensioned to operate at frequencies corresponding to millimeter-wavelength or terahertz-frequency bands of electromagnetic spectrum. It should be understood, however, that the anode slow-wave structure 12 is just one specific example from a great variety of different slow-wave structures, including electromagnetic meta-material structures, which might be dimensioned to operate at frequencies corresponding to millimeter-wavelength or terahertz-frequency bands of electromagnetic spectrum.

(11) More particularly, the anode slow-wave structure 12 has an array of rod-like elements 15 of electrically conductive material. Here, in this specific example, there are six sections 13; each section 13 includes an array of rows and columns of periodically (equally) spaced rod-like elements 15 of electrically conductive material projecting outwardly from an outer circular back-wall 17 of the anode slow-wave structure 12; one of the section 13 being separated from another one of the sections 13 by regions 14. Thus, here the sections 13 are equally spaced about the circumference of the cylindrical structure every 60 degrees and therefore have a periodicity of sixty degrees. It should be understood, however, that these regions 14 may also have an array of the rod-like elements 15. Here, for example, in each one of the sections 13 there are nine, spaced columns of the rod-like elements 15, the columns being periodically (equally) spaced along a portion of the circumference of the back-wall 17 in an X-Y plane, each column of rod-like elements 15 being disposed parallel to the Z axis, shown more clearly in FIG. 2C. Here, the nine rod-like elements 15 in each one of the six sections 13 are equally spaced about the circumference of the cylindrical structure approximately every 4.3 degrees and therefore have a periodicity of 4.3 degrees. Each one of the rod-like elements 15 projects along a radial line extending from the circular back-wall 17 of the anode slow-wave structure 12 for a predetermined radial length less than the radius of the anode slow-wave structure 12 and terminating at the interaction region 19 (the interaction region being the region between a central cathode (not shown) and distal ends of the rod-like elements 15 which is filled with the electron space charge during the operation of a high-power slow-wave vacuum electronic device), as shown. Thus, each one of the rod-like elements 15 has a proximal end terminating at the back-wall 17 and a distal end terminating at the interactive region 19. Here, for example, each one of the rod-like elements 15 has a diameter .sub.0/M, where M is between 3.5 and 4.5, and where .sub.0 is the operating wavelength of the anode slow-wave structure 12 and the rod-like elements 15 are laterally and vertically spaced one from the other a distance .sub.0/M. It should be understood, however, that the number M may be determined during the process of dimensioning the anode slow-wave structure 12 for operating at some particular frequency of interest corresponding to millimeter-wavelength or terahertz-frequency bands of electromagnetic spectrum.

(12) Thus, the anode slow-wave structure 12 includes a periodic array of rod-like elements 15 of electrically conductive material, here, in this example, the distal ends of the rod-like elements 15 equally angularly spaced one from another in the X-Y plane and equally vertically spaced one from another along a column disposed along a direction perpendicular to such plane, that is along a direction parallel to the Z axis, where the X, Y and Z axes are three mutually orthogonal axes. Thus, if the length of the anode slow-wave structure 12 along the Z axis is L, and there are N rod-like elements 15 in a column along a direction parallel to the Z axis, the rod-like elements 15 would have a periodicity of UN along the column. To put it another way, each one row of the a plurality of equally spaced rod-like elements 15 in each one of the sections 13 is disposed azimuthally about the Z-axis in a corresponding one of a spaced plurality of X-Y planes, the plurality of X-Y planes being equally vertically stacked along the Z-axis. Further, the rod-like elements 15 are disposed in the each X-Y along the Z axis project towards an interior region 19 of the anode slow-wave structure 12. Still further, the anode slow-wave structure 12, in this specific example, is a cylindrical structure and the rod-like elements 15 project along radial lines of the cylindrical structure. Further, as noted above, the regions 14 may also have an array of the rod-like elements 15; in which case, if there are R rod-like elements 15, the rod like-elements 15 would be equally spaced around the circumference of the cylindrical anode slow-wave structure 12 with a periodicity R/360.

(13) Referring now to FIG. 3, a process for rapid fabrication of the anode slow-wave structure 12 is shown using the 3D printer shown in FIGS. 4A and 4B. Here, the process will be described for rapid 3D fabrication of the anode slow-wave structure 12, it should be understood, however, that the process may be used to rapid fabrication of other slow-wave structures including anode slow wave structures, cathode slow-wave structures, as well as other meta-material structures. The process includes: (a) designing a digital three dimensional model of the slow-wave structure 12 to be fabricated by the 3D printer 24 using a computer 20 having a computer aided design program; (b) loading the digital three dimensional model of the anode slow-wave structure 12 into a memory 22 of the 3D printer 24 (such as manufactured by Optomec Design Company, Albuquerque, N. Mex., www.optomec.com), the loaded digital three dimensional model having data therein representative of the anode slow-wave structure 12 to be fabricated by the 3D printer 24; (c) loading metal powder material 21 from a powder supply/sprayer 23, here the metal powder material is an electrically conductive metal powder material of, for example, stainless steel, into the 3D printer 24; (d) operating the 3D printer 24 to deposit a layer 16 of the metal powder material 21 onto an open can-like, powder holding container 27, as shown in FIG. 4A; (e) melting the deposited layer 16 of the metal powder material 21 with a moveable, focusable laser (or electron) beam 25 (FIG. 4B) produced by the laser (or electron) beam source 26 of the 3D printer 24 in accordance with the loaded three dimensional model of the anode slow-wave structure 12 to transform the layer 16 of metal powder material into the layer 16 of melted metal; (f) solidifying the layer 16 of melted metal after moving the laser (or electron) beam 25 thereby allowing the layer 16 of melted metal to cool and thereby transform the layer 16 of melted metal into a layer 16 of solid metal shaped in accordance with the loaded three dimensional model of anode the slow-wave structure 12; and (g) repeating (c) through (f) to fabricate the anode slow-wave structure 12 layer 16 by layer 16 until completion of the anode slow-wave structure 12 fabrication. It should be noted that each one of the layers 16 of the metal powder material has a thickness at least ten times less than the lesser of predetermined dimensions each one of the rod-like elements 15 and/or the predetermined distance between these rod-like elements 15. The layer 16 of solid metal by layer 16 of solid metal buildup is shown in FIGS. 6A-6G. After fabrication of the anode slow-wave structure 12, the remaining, non-solidified metal powder material 21 is removed from the powder holding container 27 (FIG. 3, (h)).

(14) It is noted in FIG. 4B that the laser (or electron) beam 25 is focused to a focal point at the level of the metal powder material 16 in one layer, then at that focal point, moves in a specific pattern determined by the loaded three dimensional model of the anode slow-wave structure 12, such as, for example, a circular pattern, starting at a predetermined distance from the inner vertical sidewall of the powder holding container 27 with the greatest diameter and then sequencing inwardly with successively smaller diameter and stopping at the distal end of the anode slow-wave structure 12 having completed the transformation of the metal powder material 16 into the layer of solid metal 16; a new layer 16 of metal powder material is deposited; and then the laser (or electron) beam returns to the outer diameter and is focused at a higher focal point along the Z axis on the new layer 16 of the metal powder material to repeat the process.

(15) Thus, referring to FIG. 5A, a first layer (layer #1) of the metal powder material is deposited onto the bottom surface of the open can-like, powder holding container 27. Next, referring to FIG. 5B, the laser (or electron) beam melts the portions of the deposited metal power material in layer #1 to form a first layer of the back-wall 17 and the rod-like element 15, extending outwardly therefrom towards, and terminating at the interaction region 19, in one of the rows thereof for each of the six anode sections 13. After the portions of the layer 16 of metal powder material are melted they are solidified after moving the laser (or electron) beam thereby allowing the melted metal to cool, a first layer of the back-wall 17 and the row of rod-like elements 15 are formed, as shown in FIG. 5B. It is noted that metal powder material 16 remains between the outer portion of the rod-like element 15 and the inner sidewall of the powder holding container 27.

(16) Next, a second layer of metal power material (layer #2) is deposited, as shown in FIG. 5C. Next, referring to FIG. 5D, the laser (or electron) beam melts portions of the deposited layer #2 of metal powder material to form a second layer of the back-wall 17. After the melted portions of layer 2 of metal powder material are solidified, the second layer of the back-wall 17 is formed as shown in FIG. 5D. It is noted that metal powder material 16 remains between the outer portion of the back-wall 17 and the inner sidewall of the powder holding container 27.

(17) Next, a third layer of metal powder material (layer #3) is deposited, as shown in FIG. 5E. Next, referring to FIG. SE, the laser (or electron) beam melts portions of the deposited layer #3 of metal powder material to form a third layer of the back-wall 17 and the rod-like element 15, extending outwardly therefrom towards, and terminating at, the interactive region 19, in second of the rows thereof for each of the six anode sections 13. After the melted portions of the layer #3 of metal powder material is solidified, a first layer of the back-wall 17 and the second row of rods 15 are formed, as shown in FIG. 5F. It is again noted that metal powder material 16 remains between the outer portion of the rod-like element 15 and the inner sidewall of the powder holding container 27.

(18) The process described above is repeated until the anode slow-wave structure is fabricated. It is noted that metal powder material 16 remains between the outer back-wall 17 and the inner sidewall of the powder holding container 27 thereby enabling the fabricated anode slow-wave structure described in FIGS. 2A-2C to be vertically oriented inside the powder holding container 27.

(19) It should be understood, however, that the process described above in connection with FIGS. 5A-5F would produce rod-like elements 15 having rectangular cross sections. If the rod-like elements 15 having either circular or any other cross-sections are desired, the circular or any other cross sections are approximated by a series of rectangular sub-layers 16a, as shown in FIG. 6. Thus, in order to fabricate one such rod-like element 15 a sequence of rectangular metal sub-layers 16a must be used by converting metal powder material sub-layers 16a into the solid metal sub-layers 16a using the laser (or electron) beam. More particularly, consider that the single rod-like element 15 has a circular cross-section with a diameter .sub.0/M. The rod-like element 15 are made up of a plurality of thin layers, here for example, ten thin layers, each one having a thickness 0.1.sub.0/M. The lower sub-layer 16a is formed having a thickness 0.1.sub.0/M and a suitable width to approximate the outer circular perimeter (shown dotted in FIG. 6) of the circular cross section of the rod-like element 15. Next, the second sub-layer 16a is formed on the lower sub-layer 16a having a thickness 0.2.sub.0/M. The process repeats increasing the thickness and a suitable width to approximate the outer circular perimeter (shown dotted in FIG. 6) of the circular cross section of the rod-like element 15 of the sub-layers 16a step by step until the sub-layer 16a having a thickness 0.5.sub.0/M and a width 0.5.sub.0/M is formed. Next, the process repeats decreasing the thickness and width of the sub-layers step by step until the upper sub-layer 16a having a thickness 0.1.sub.0/M and a suitable width to approximate the outer circular perimeter (shown dotted in FIG. 6) of the circular cross-section of the rod-like element 15. This completes the fabrication of one rod-like element 15.

(20) It is also noted that the portions of the back-wall 17 from which the rod-like element 15 extend and which are integrally formed is also formed using the stepped process described above. The portions of the back-wall 17 between the rod-like elements 15 may be formed with ten layers each having a thickness of 0.1.sub.0/M or one layer having the thickness of .sub.0/M in one step.

(21) As noted above, the use of 3D printing process enables rapid fabrication of anode slow-wave structures and test a variety of parameters such as the dimensions of the rod-like elements 15, the azimuthal and vertical periodicity of the rod-like elements 15, the number of the rod-like elements 15, and the value of M for operating at particular frequency of interest corresponding to millimeter-wavelength or terahertz-frequency bands of electromagnetic spectrum during design/simulation phases of the anode slow-wave structures design process. Thus, a method is disclosed for rapid fabrication of anode slow-wave structures, including electromagnetic metamaterial structures comprising: using a computer having a computer aided design program to design the digital three dimensional model of the slow-wave structure; loading the digital three dimensional model of the anode slow-wave structure in a memory of a 3D printer; operating the 3D printer with the loaded digital three dimensional model of the anode slow wave structure to fabricate the anode slow wave structure in accordance with the loaded digital three dimensional model of the anode slow wave structure; and testing the fabricated anode slow wave structure.

(22) A number of embodiments of the disclosure have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the disclosure. For example, while the anode slow-wave structure has been shown having a circular configuration, the anode slow-wave structure may be fabricated by a 3D printer having other configurations as, for example, linear three dimensional slow-wave structures for operation in travelling wave or backward-wave tubes. Furthermore, not only anode slow-wave, including electromagnetic meta-material structure may be fabricated using 3D printing process, but, for example, cathode slow-wave structures such as, for example, cathode meta-material slow-wave structures, or, for example, different electromagnetic meta-material structures. Accordingly, other embodiments are within the scope of the following claims.