Machining of terahertz split-block waveguides with micrometer precision

Evolutionary improvements in tooling and techniques are allowing increasingly complicated waveguide circuits to be fabricated with conventional end-mill machining at frequencies ranging from millimeter-wavelengths up to several terahertz. Machining precision is now approaching the limits of what can be measured with an optical microscope, with the measured dimensions of the highest-precision components typically within 2 mum of the nominal design values. We summarize the capabilities of the Space Instruments Shop at JPL and show examples of recently machined components.