In this paper, a new type of simple and inexpensive
waveguide filter manufacturing that minimizes material
consumption and has capabilities of high performance and rapid prototyping is presented. Filter inserts are fabricated by a combination of additive dielectric manufacturing and subtractive metal manufacturing, whereas standard waveguides are used as housings, utilizing best properties of each technology. Along with it, a suitable filter design using metal rectangular rings has been developed. Since the rings that act as positive reactance discontinuities in the passband are resonant at frequencies below it, it is possible to bring lower stopband transmission zeros near
the passband to create sharp skirt. A resonator of such a filter and a third order bandpass filter sample have been designed at 11.13 GHz and 11.36 GHz centre frequencies respectively. In addition, smaller size rectangular rings in waveguide can realize upper stopband transmission zeros while acting as negative reactance discontinuities in the passband. This was utilized in fourth order bandpass filter at 11.36 GHz centre frequency with finite transmission zeros in both stopbands. All the filtering structures have been fabricated with 3D printer to extrude polylactic acid and circuit board plotter to mill copper sheet, and tested. Excellent measurement results that have been obtained validate the proposed design. Practical sides of achieving quality 3D printouts are analysed.