Abstract: Methods of fabricating air-filed true-time-delay, continuous transverse stub array antenna. A plurality of extruded sections that are physically independent of one another are fabricated. The plurality of extruded sections are arranged in a predefined pattern defining the structure of the array antenna. Adjacent surfaces of the extruded sections form waveguides of the array antenna. The plurality of extruded sections are joined together at their respective ends to form the array antenna. The plurality of extruded sections may be joined using a plurality of end plates. The plurality of extruded sections and end plates may comprise metal or plastic. If the extruded sections are plastic, they are metallized 44 using a process such as vacuum deposition, electroless plating, or lamination during the extrusion process. The end plates are sealed to the extruded sections to form the array antenna structure.

Abstract: An improved injection molded radiator assembly and antenna assembly can be made using multiple such radiator assemblies. The radiator assembly includes an injection molded radiator enclosure that forms an RF waveguide channel. A circuit/RF probe subassembly is mated to the radiator enclosure that houses a circulator assembly, input and output connectors, and an RF probe. An environmental plug is disposed in the radiator enclosure to seal the RF waveguide channel from the external environment.

Abstract: A microwave radar antenna that substantially comprises molded or extruded thermoplastic components that are assembled into completed assemblies, are then metallized by either electroless copper or are electroplated with copper to achieve RF conductivity. The finished subassemblies are joined together forming the completed antenna. The molded, metallized, plastic antenna uses a thermoplastic material, such as polyetherimide, or suitable high strength, high temperature thermoplastic that is used to injection mold or extrude detailed microwave components. The molded components are assembled, using epoxy adhesives, solvents or other mechanical method into microwave subassemblies. These subassemblies are then either electroless copper plated or electroplated to provide RF conductivity. The metallized subassemblies are then joined together using mechanical methods to form a completed radar antenna, replacing heavier more costly metal radar antennas.

Abstract: A microwave assembly having molded thermoplastic components that are first assembled into an enclosure, and then electroless copper plated to provide for RF conductivity. Assemblies are made by bonding bare thermoplastic components, after which the bonded assembly is electroless copper plated. The components are made of an injection molding material, polyetherimide, or a high strength, high temperature thermoplastic. The components are assembled using a one component epoxy adhesive, for example. All components are designed to be self locating to aid in assembly. A bonding fixture is used to apply clamping pressure to the components while the adhesive cures. After bonding, the waveguide assembly has its critical flange surfaces finish machined prior to plating.

Abstract: A method of fabricating a microwave waveguide component wherein a plurality of joinable thermoplastic members are first formed. The members, when joined, comprise a microwave waveguide component having an internal surface that is adapted to be plated. The thermoplastic members are then bonded together. Then, the internal surface is plated to form the finished microwave waveguide component. The present method forms microwave components from plated, injection molded thermoplastic and reaction injection molded thermosetting plastics. In particular, the plastic components made using the present invention exhibit comparable electrical performance, as measured by voltage standing wave ratio (VSWR) and insertion loss, decreased device weight and cost, and reliable and repeatable manufacturability when compared with devices formed using metals, conventional thermosetting plastics that have been metallized, and molded, plated and soldered thermoplastics.