Abstract: A technique for manufacturing a domed housing, including a transreflector element for use in a microwave antenna. The dome incorporates a metallic polarizing grid as part of a complex curved shape using an insert mold process. As a result, the transreflector component can be inexpensively formed as an integral part of the supporting structure and any alignment features, without the need for additional molding steps or multiple component parts.

Abstract: A transreflector is made by forming a series of spaced parallel stripes of a conductive material on one surface of a synthetic resin carrier film. The film is placed against the surface of a mold defining the desired concave internal curve for the transreflector, and the mold cavity is closed by placing over the film in spaced relationship a second mold half having the desired convex external curve for the transreflector. A fluid synthetic resin is introduced into the mold cavity to form the desired transreflector element with spaced parallel stripes disposed on the internal concave surface thereof. The carrier film is removed from the transreflector element with the conductive material stripes remaining on the transreflector element.