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Three‐dimensional photonic bandgap (PBG) structures using alumina (Al₂O₃) as the high permittivity material were modeled and then the structures were fabricated by Fused Deposition of Multi‐materials (FDMM) technology. A finite element method and a real‐time electromagnetic wave propagation software were used to simulate and design the layered PBG structures for applications in the microwave frequency range. The modeling predicted a 3‐D photonic bandgap in the 16.5–23.5 GHz range. FDMM provides a computer‐controlled process to generate 3‐D structures, allowing high fabrication flexibility and efficiency. Electromagnetic measurements displayed the presence of a bandgap between 17.1–23.3 GHz, showing a good agreement with the predicted values. These PBG structures are potential candidates for applications in advanced communication systems.

The purpose of this paper is to present a novel and effective fabricating method of 3D ceramic photonic crystals with diamond structure.

The reverse diamond‐structure resin molds are fabricated by stereolithography (SL), then ceramic slurry is prepared and injected into the molds under vacuum condition. Subsequently, ceramic photonic crystals are obtained after vacuum freeze‐drying and sintering.

The combination of SL, gel‐casting and freeze‐drying could be used to fabricate the 3D ceramic photonic crystals with diamond structure which have intact structure and minimal shrinkage. The samples have been tested and the experimental results indicate that their band gap is in the range of 10.14‐12.20 GHz, consistent with the simulation results.

The influence of fabrication process on the photonic band gap needs further study.

This paper presents a novel fabricating method of 3D diamond‐structure ceramic photonic crystals based on SL, gel‐casting and freeze‐drying. The method fabricates complex ceramic photonic crystals with high accuracy and helps further research in this field.