How 3D-Printing Is Changing RF Front-End Design for Space Applications

Abstract

3D-printing is leading to a major transformation in many industrial and application sectors, ranging from medical to aerospace. In the space sector, 3D-printing has firstly been adopted for the development of structural and thermal parts, such as brackets and heat pipes. In more recent years, thanks to improvements in precision and surface roughness, 3D-printing technologies have steadily been investigated also for the development of radio frequency components and advanced payloads. Indeed, the unique features of 3D-printing, including the free-form capability and the ease for customization, make these manufacturing technologies very appealing in the development of complex radio-frequency front-ends for space applications, including New Space constellations and next generation software-defined communication satellites. They also enable a drastic simplification of mechanical designs by reducing the number of interfaces and assembling screws of large radio-frequency front-ends, thus leading to significant mass savings and higher integration. This paper briefly reports on recent advances in 3D-printing that have been carried out according to the current trends in radio-frequency front-ends for satellite communications.

Fully-Metallic Additively Manufactured Monolithic Double-Ridged Waveguide Rotman Lens in the K/Ka-Band

“…For the prototype reported here, laser powder bed fusion (LPBF) AM was chosen [ 40 ]. LPBF involves the sequential deposition of metal powder layers, AlSi10Mg aluminum alloy in this case, with each layer having a height range of approximately 20–30 µm.…”

“…LPBF involves the sequential deposition of metal powder layers, AlSi10Mg aluminum alloy in this case, with each layer having a height range of approximately 20–30 µm. The choice of material was driven here by the targeted space applications, with antenna systems often exposed to the harsh space environment, thus requiring components providing a good compromise between electrical and mechanical properties [ 40 ]. The uniform deposition of the metal powder on the printing bed is accomplished using a recoater.…”

“…While AM technologies provide some flexibility in the RF design by removing mechanical interfaces and simplifying the overall assembly, they do introduce some printing constraints, which require careful consideration [ 40 ]. The most important parameter to be defined is the printing direction, expected to provide a stable PPW thickness without requiring excessive supporting structures.…”