In this waveguide horn antenn component, a slanted through-slot must be cut using Wire-EDM.
However, the original waveguide port extension was too long, and the EDM wire would directly intersect the port wall, causing severe structural damage and RF degradation.
Problem
The EDM path (red line) intersects the mechanical extension of the port:
Risk of cutting into the port wall
Dimensional shift of the internal cavity
Reflection & insertion loss degradation
Potential part scrap
Optimization Strategy
We analyzed the design from both RF and machining perspectives:
Preserve RF-critical dimensions
Effective waveguide length
Shoulder position
Cross-section dimensions
Shorten the non-critical mechanical extension
Simulation confirmed that trimming the extension to the blue region has negligible RF impact.
Final Solution
The waveguide port length was shortened to avoid the Wire-EDM path while maintaining all RF-critical geometry.
Result
No interference during Wire-EDM
Zero damage to the port wall
Electrical performance fully preserved
Higher yield and lower rework risk
Engineering Insight
RF design and machining constraints must be co-optimized.
Non-critical mechanical features should be adjusted to ensure manufacturability without sacrificing high-frequency performance.