We have demonstrated a waveguide-fed, W-band horn antenna using a three-dimensional (3D), polymeric micro hot embossing process. Two cavity resonators were designed to reduce the impedance mismatch between the horn antenna and the feeding waveguide at a 90° bend. High Frequency Structure Simulator (HFSS) was used to simulate for the performance of the waveguide-fed horn antenna. The antenna directivity and return loss at 95GHz were simulated at 16.56dB and 14.5dB respectively. The measured performance shows impedance match better than 10dB between 76.5~101.7 GHz and 17.5dB at 95GHz. The 3dB beamwidths of the E- and H-plane patterns are 26° and 23° respectively and the total directivity is 17.33dB. The cross-polarized component in the E- or H-planes was 20dB lower than the peak of the corresponding co-polarized component indicating the antenna robustness in rejecting signals with undesired polirization. This plastic, low-cost manufacturing process opens up opportunities in replacing the expensive metallic components with integrated 3D polymeric manufacturing for current and future millimeter-wave systems.

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