To accommodate the ever-growing data requirements in densely populated areas and address the need for high-resolution sensing in diverse next-generation applications, there is a noticeable trend towards utilizing large unallocated frequency bands above 100 GHz. To overcome the harsh propagation conditions, large-scale antenna arrays are crucial and urge the need for cost-effective, mass-manufacturable technologies. A dedicated Any-Layer High Density Interconnect PCB technology for highly efficient wireless D-band (110-170 GHz) systems is proposed. Specifically, the adapted stack accommodates broadband air-filled substrate-integrated-waveguide components for efficient long-range signal distribution and low-loss passives. The viability of the suggested technology platform is demonstrated by designing, fabricating and measuring several essential low-loss air-filled substrate-integrated-waveguide components, such as a dual rectangular filter, with a minimal insertion loss of 0.87 dB and 10 dB-matching within the (132.8-139.2 GHz) frequency band, and an air-filled waveguide with a routing loss of only 0.08 dB/mm and a flat amplitude variation within 0.01 dB/mm over the (115-155 GHz) frequency range. A broadband transition towards stripline, with a limited loss of 1.1 dB, is described to interface these waveguides with compactly integrated chips. A tolerance analysis is included as well as a comparison to the state of the art.
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