Planar Waveguide Vent

Planar Waveguide Vent Material Choices – Aluminum, Stainless Steel, Plating Effects

Aluminum is the first thing most people reach for. Light, conductive, easy to machine. Works for most airflow designs. Fine.

Problem is, thin walls flex. Mounting screws tighten down. Vibration happens. Over time, geometry shifts a bit. Not huge, but in tight EMC margins, it shows up.

Stainless steel behaves differently. Heavier, less conductive. But it doesn’t bend as easily. Thermal cycles, repeated handling – geometry stays put. You trade weight for predictability. Often worth it in aerospace or rugged systems.

Surface treatment – don’t underestimate it. Plating adds corrosion resistance, better contact. But thickness varies. Tiny difference in coating can change how the waveguide attenuates EMI. Nickel, silver, tin – pick based on process control, not theory. Stable is better than peak.

Strength matters. Soft material → thicker walls → less open area. Stronger material → thinner walls → higher cost or weight. That affects airflow, vibration tolerance, installation robustness. Also affects how forgiving the vent is when reality diverges from CAD.

EMC performance isn’t just about “geometry works on paper.” Material participates in the shielding path. Aluminum, steel, plated variants – all choices influence how consistent attenuation is over time.

Rule of thumb: geometry sets potential, material sets reality. Ignore it at your peril.