Additively Manufactured Tracking Antenna Array for Low-SWaP Satellites
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Solution Overview
Problem
Traditional fabrication methods for hollow metal waveguide antennas result in large sizes, high weights, and increased complexity, leading to reduced performance and increased costs, which are particularly challenging for small satellites and other applications requiring high data rates and signal integrity.
Innovation Solution
An integrated antenna array is constructed using additive manufacturing processes, forming a plurality of radiating elements and combiners as a single indivisible metal element, incorporating structural lattice for strength and heat dissipation, and integrating mechanical positioning elements to meet electromagnetic and thermal performance metrics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional fabrication methods are used for hollow metal waveguide antennas, then structural strength is improved, but size and weight increase significantly
Solution Approach 1:
The patent applies lattice structures (porous metal structures) to create antenna elements that are significantly lighter than solid hollow waveguide constructions while maintaining structural integrity. The lattice geometry provides strength through distributed load paths while removing excess material, directly resolving the contradiction between strength and weight.
Solution Approach 2:
The patent combines metal lattice structures with dielectric materials to create composite antenna elements. This composite approach allows optimization of each material for its specific function (metal for structural strength and RF conductivity, dielectric for electromagnetic properties) while achieving lower overall weight compared to traditional solid metal waveguide constructions.
2Ease of manufacture
If traditional multi-piece fabrication methods are used, then ease of assembly is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent merges multiple antenna elements, support structures, and mounting features into single monolithic printed components. This consolidation eliminates the need for multiple assembly steps, fasteners, and joints, reducing both manufacturing complexity and assembly difficulty while maintaining structural strength through the additive manufacturing process.
Solution Approach 2:
The patent replaces traditional mechanical assembly methods (fasteners, welds, adhesives) with additive manufacturing processes that create monolithic structures. This substitution eliminates the complexity of mechanical joining while maintaining or improving structural integrity through the layer-by-layer fabrication process.
3Weight of stationary object
If antenna size is reduced for small satellite applications, then SWaP constraints are improved, but signal integrity and performance may deteriorate
Solution Approach 1:
The patent changes the fundamental parameters of antenna construction by using additive manufacturing to create lattice structures with optimized cell sizes and wall thicknesses. These parameter changes enable reduced mass and volume while maintaining the electrical and mechanical properties necessary for signal integrity in small satellite applications.
Solution Approach 2:
The patent applies local quality optimization by varying the lattice structure density and geometry in different regions of the antenna elements. This allows critical RF paths to maintain higher structural fidelity for signal integrity while non-critical regions use more aggressive material removal for weight reduction, resolving the contradiction between size and performance.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution reduces the size and weight of antennas while maintaining high performance, enabling integration of multiple physical requirements into a single component, suitable for small satellites and other applications with SWaP constraints.
Implementation Method 1
incorporating structural lattice for strength and heat dissipation
Implementation Method 2
heat dissipation
Implementation Method 3
A plurality of radiating elements and combiners may be formed together as a single indivisible element
Implementation Method 4
At a particular wavelength (which is inversely proportional to the frequency by the speed of light λ=c/f) for a particular length of wire, the wire will resonate in response to being exposed to the transmitted signal
Data Source
AI summary
An antenna array is provided that includes a plurality of radiating elements and one or more combiners. The plurality of radiating elements and the combiners are formed as a single indivisible metal element by use of additive manufacturing processes.