Abstract:
This paper presents the design, fabrication, and experimental validation of a dual-band linear-to-circular
polarization converter based on a 3D frequency selective surface and tailored for K/Ka-band satellite
communication systems. The proposed solution, based on a transverse electromagnetic (TEM) cell topology, is
realized through additive manufacturing using Stereolithography Apparatus (SLA) combined with copper
metallization, achieving a lightweight and low-loss structure with complex 3D geometries. The device,
integrated directly on the the feed aperture, effectively covers both the transmit K-band (17.3–20.2 GHz)
and receive Ka-band (27.5–30.0 GHz) sub-bands, demonstrating axial ratios (AR) below 1.1 dB in the TX and
in the RX band, with reflection losses better than 17 dB. The polarizing screen demonstrates outstanding
broadband or dual-band behavior under periodic boundary condition simulations (AR < 3 dB and IL < 0.25 dB
in broadband mode; AR < 1.1 dB and IL < 0.15 dB in dual-band mode). This work represents a first step toward
the direct integration of polarizing screens onto radiating apertures, enabling compact, high-efficiency
antenna designs for future phased array platforms. The paper also discusses fabrication challenges, thermal
reliability, and a sensitivity analysis confirming robustness against manufacturing tolerances, highlighting
the potential of 3D printing for advanced satellite antenna subsystems.
