Abstract: An “inside out” process is used to make RF antennas and components or higher frequency components and/or optics. An electroformed single or multi layer of metal, such as copper, is applied to a reusable or disposable mandrel. Additional metal or composite components and/or pieces may be attached to the electroform by means of further electroforming, and/or applying adhesive and/or soldering. Any composite material (for example, fiberglass or carbon fiber reinforced plastic) is then applied selectively or uniformly around the electroform and/or additional components for structural reinforcement, and/or enhancement of thermal stability and/or thermal conductivity. The mandrel is then removed by physical or chemical means. Adhesion over temperature and humidity extremes, surface finish, uniform metalization thickness, and surface electrical conductivity are all vastly improved over equivalent electroplated composites.

Abstract: An “inside out” process is used to make RF antennas and components or higher frequency components and/or optics. This invention is especially useful for spaceflight components requiring high performance at low weight, components requiring high specific stiffness and/or strength and components requiring high performance, precision or stability. An electroformed single or multi layer of metal, such as copper, is applied to a reusable or disposable mandrel. Additional metal or composite components and/or pieces may be attached to the electroform by means of further electroforming, and/or applying adhesive and/or soldering. Any composite material (for example, fiberglass or carbon fiber reinforced plastic) is then applied selectively or uniformly around the electroform and/or additional components for structural reinforcement, and/or enhancement of thermal stability and/or thermal conductivity. The mandrel is then removed by physical or chemical means.