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This paper presents the impact of surface roughness on the performance of a three –dimensional (3D) metal printed waveguide coupler designed at 28 GHz. The surface roughness is a significant factor that may affect 3D printed structures and post processing may be needed. It may degrade the performance of the printed devices in term of the reflection coefficient and increases the insertion loss. Thus, this work analyses the surface roughness impact on the 3D metal printed coupler designed at 28 GHz. The hybrid coupler is a waveguide-based structure with coupled resonators and the coupling is controlled by tuning the iris dimensions. The measurement is done without any post processing procedure to ensure the validation of the printed coupler with simulation results. The surface roughness measurement is performed with six tested areas of coupler structure using advanced 3D optical microscope. Then, the …