This paper introduces shape deformation as a new approach to the computer-aided design (CAD) of high frequency components. We show that geometry deformation opens up new design possibilities and offers additional degrees of freedom in the 3D modeling of microwave structures. Such design flexibility is highly desirable if the full potential of Additive Manufacturing (AM) is to be exploited in the fabrication of RF & microwave devices. The use of deformation techniques in the design of high-frequency components allows the attainment of improved electrical parameters, such as high-quality factors for cavity resonators and wide higher-order mode separation. In this work, shape deformation with radial basis functions (RBFs) is integrated with an electromagnetic field simulator based on the 3D finite-element method (FEM), allowing the semiautomated optimization of microwave components, such as cavity resonators and filters. The proposed strategy is used for the design of high Q-factor cavity resonators, cavity bandpass filters with improved spurious mode separation and of a compact twisted waveguide filter. Three designs of waveguide cavity filters with complex geometry are experimentally verified using 3D-printed prototypes fabricated with the selective laser melting (SLM) technology.
