In the context of exploring the possibility of using Al-powder Selective Laser Melting to fabricate horn antennas for astronomical applications at millimeter wavelengths, we describe the design, the fabrication, the mechanical characterization, and the electromagnetic performance of additive manufactured horn antennas for the W-band. Our aim, in particular, is to evaluate the performance impact of two basic kinds of surface post-processing (manual grinding and sand-blasting) to deal with the well-known issue of high surface roughness in 3D printed devices. We performed comparative tests of co-polar and cross-polar angular response across the whole W-band, assuming a commercially available rectangular horn antenna as a reference. Based on gain and directivity measurements of the manufactured samples, we find decibel-level detectable deviations from the behavior of the reference horn antenna, and marginal evidence of performance degradation at the top edge of the W-band. We conclude that both kinds of post-processing allow achieving good performance for the W-band, but the higher reliability and uniformity of the sand-blasting post-process encourage exploring similar techniques for further development of aluminum devices at these frequencies.

在探索使用铝粉选择性激光熔融技术制造毫米波长天文应用的号角天线的可能性的背景下，我们描述了用于W的增材制造的号角天线的设计，制造，机械特性和电磁性能-带。我们的目标尤其是评估两种基本类型的表面后处理（手动打磨和喷砂）对性能的影响，以解决3D打印设备中众所周知的高表面粗糙度问题。我们以市售矩形喇叭天线为参考，对整个W波段的同极和交叉极角响应进行了对比测试。根据制造样品的增益和方向性测量，我们发现与参考号角天线行为的分贝级可检测到的偏差，以及在W波段顶部边缘性能下降的边际证据。我们得出的结论是，两种后处理都可以使W波段获得良好的性能，但是喷砂后处理的更高可靠性和均匀性鼓励探索类似的技术，以便在这些频率下进一步开发铝制设备。