In this letter, a parallel-plate waveguide half-Luneburg geodesic lens multiple-beam antenna optimized for additive manufacturing is designed and validated experimentally in the Ka-band. Two prototypes were manufactured in AlSi10Mg through laser powder-bed fusion and measured in an anechoic chamber. The compact and lightweight prototype optimized for additive manufacturing demonstrates excellent RF performance while significantly reducing mass and mechanical complexity. Specifically, misalignment errors present in previous studies are solved, improving side lobe level by up to 10 dB. A maximum realized gain of 22.1 dBi is measured at 28 GHz. This singlepiece, compact and lightweight design is particularly attractive for applications having mass restrictions and limited space like millimetre-wave systems on board small satellites.

This paper reports on the design and experimental validation of a fully-metallic double-ridged waveguide 10 × 10 Rotman lens additively manufactured as a single part. The wide band operation of this quasi-optical beamformer enables us to cover the uplink and downlink frequencies allocated to satellite communications in the K/Ka-band, from 17.3 GHz to 30 GHz. The feeding port design was adjusted to enable vertical printing, thus minimizing the use of supporting structures. A prototype was manufactured and tested. The reported results indicate losses in the range of 0.5 dB in the lower-frequency band and 0.8 dB in the upper-frequency band, including the waveguide transitions added for test purposes. The measured reflection and coupling coefficients remain below −11.5 dB over the operating band. The standard deviation of the residual phase error across the array ports is below 5° in simulation and below 10° in measurements. Array factors synthesized using the scattering parameters confirm the good stability of the beamforming functionality over the wide frequency band analyzed. This monolithic design is a promising step toward more integrated antenna systems, such as a compact dual-stack configuration for planar array design.

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