Additive manufacturing (AM) technology has great potential in manufacturing complex internal channels for several applications such as satellite-communication microwave systems. These systems can have complex shapes and make traditional finishing processes a challenge for additive parts. Therefore, it is desirable that the internal surfaces are as close as possible to the tolerance of the field of application. In this study, a complex component, a unique waveguide device with bending, twisting and filtering functionalities, has been designed and manufactured in AlSi10Mg alloy through laser powder bed fusion (L-PBF) process. Three different prototypes with three different curvature (R of 50 mm, 40 mm and 30 mm), operating in Ku/K band, have been manufactured and tested showing a very good agreement with the desired performances. Using 3D scan data, the internal deviations from the CAD model have been evaluated showing an average deviation of the internal areas of about 0.08 mm, 0.046 mm and 0.023 mm from the CAD model for the R of 50 mm, 40 mm and 30 mm respectively The surface roughness measured in the internal channel is about R_a (arithmetic average roughness) of 8 μm ± 1.3 μm and R_z (average maximum height of the roughness profile) of 62.3 μm ± 0.34 μm.

增材制造（AM）技术在制造用于多种应用（例如卫星通信微波系统）的复杂内部通道方面具有巨大潜力。这些系统可能具有复杂的形状，并使传统的精加工工艺成为增材制造的挑战。因此，期望内表面尽可能地接近应用领域的公差。在这项研究中，已经通过激光粉末床熔合（L-PBF）工艺在AlSi10Mg合金中设计和制造了复杂的组件，即具有弯曲，扭曲和滤波功能的独特波导器件。具有三个不同曲率（R的三个不同原型在Ku / K波段操作的50mm，40mm和30mm的光纤（已制成50mm，40mm和30mm）已显示并与所需性能非常吻合。使用3D扫描数据，已评估了与CAD模型的内部偏差，对于50 mm，40 mm和30 mm的R，内部面积与CAD模型的平均偏差分别约为0.08 mm，0.046 mm和0.023 mm在内部通道中测得的表面粗糙度约为8μm±1.3μm的R _a（算术平均粗糙度）和62.3μm±0.34μm的R _z（粗糙度轮廓的平均最大高度）。