A DFMA-based manufacturing plan and the material selection for a 22.7 GHz cylindrical cavity resonator

Abstract

This thesis studies the design and manufacture of 22.7 GHz cylindrical cavity resonators using the DFMA-based method. Through literature review, expert interviews and simulation, this study integrates geometric modeling, material selection and CAM verification to balance RF performance and manufacturing feasibility. The cavity structure combines stainless steel, copper and brass components and is Improved for thermal compatibility and electrical conductivity. The SolidWorks DFM tool and UG NX simulation revealed the key process constraints, which were addressed through design adjustments and post-weld improvements. The results emphasize the leading role of cavity diameter in frequency determination and demonstrate how the DFMA principle can be effectively applied to high-frequency microwave devices.