Relevant Information: The design of the system was carried out in view of its monolithic manufacturing through additive manufacturing (AM),
and in particular laser powder bed fusion (L-PBF). An EOSINT M270 Dual-mode system has been used. This machine is equipped with a 200 W
Yb-fiber laser. During the manufacturing process, the building chamber is filled with an inert gas (argon) in order to keep the oxygen content
less than 0.10 %. The main L-PBF process parameters used are: a power of 195 W, a layer thickness of 30 micrometer, a hatching distance of
0.17 mm, and a scanning speed of 800 mm/s. The scanning direction is rotated by 67° with respect to the previous layer. Correct optimization
of process parameters, such as scanning options and beam offset, allows for a dimensional accuracy within 0.04 and 0.07 mm.

Finishing Process: After the building process by L-PBF, the part is subjected to a stress-relieving process and then is detached from the building
platform. The stress-relieving process (2h at 300°C in air) allows for reducing the risk of deformation and wrapping of the part when it is
detached from the platform. These effects can be generated by the high stresses arisen during the high-power building process that actually
melts the metal powders.

Finally, the part is subjected to micro shot-peening to remove any residual powder from the internal channels, to reduce the surface roughness
and, hence, the equivalent surface electrical resistivity. For AlSi10Mg alloy, an equivalent surface electrical resistivity of approx. 10–20 μΩ
could be obtained.
For radio frequency (RF) applications, such as satellite communication, asking for high dimensional accuracy and low electrical resistivity, both
post-processings are mandatory.

Chemical Composition: AlSi10Mg0.3 alloy