Waveguide components of waveguides formed with additive manufacturing

A method, for forming a radio frequency (“RF”) waveguide device by additive manufacturing, the method comprising:

• fabricating a RF channel comprising at least one wall;
• and
• fabricating a RF component comprising an unsupported span extending from the at least one wall of the RF channel, wherein the unsupported span is formed at least in part by building up a first unsupported surface to extend from one of the at least one wall at a first oblique angle relative to the angle and a second unsupported surface to extend from one of the at least one wall at a second oblique angle, wherein the first and second unsupported surfaces join together at an apex between the first and second unsupported surfaces,
• wherein the unsupported span is fabricated without the use of an underlying supporting structure, wherein the unsupported span is completed using additive manufacturing without post processing machining,
• wherein the RF component comprises a waveguide splitter disposed within a horn section of the RF channel, and wherein the first and second unsupported surfaces join together to form a chevron profile on the waveguide splitter.