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Lee-Yow C.,Custom Microwave Inc.
28th AIAA International Communications Satellite Systems Conference, ICSSC 2010 | Year: 2010

The need for compact high performance reflector antenna feeds for space application will always be around as long as low mass and small envelopes are desirable features. Custom Microwave Inc., CMI, uses precision CAD tools along with electroforming to realize compact high performance feeds for reflector antennas. Precision CAD tools are used to perform RF and mechanical design. These tools are well proven and have been used successfully to design complex feeds for satellite application at CMI over the past 10 years. Electroforming is a manufacturing technique ideally suited for the fabrication of complex hardware in a small package that requires low Passive Intermodulation Products (PIM) performance. By allowing the various components to be closely integrated in a single piece, electroforming makes it possible to realize the feed with a minimum number of joints. This not only provides for low PIM but often results in high performance feeds with envelopes that are smaller than what is possible with other manufacturing techniques. Electroforming provides very high mechanical precision, which eliminates the need for tuning screws thereby allowing for higher peak power handling. These features also make electroforming ideally suited for the fabrication of millimeter and sub-millimeter wave feeds and components. CMI has used precision CAD along with electroforming to produce compact high performance feeds for reflector antennas for a wide variety of space applications such as remote sensing, exploration, commercial and military communication. These feeds are realized without the need for prototyping and bench tuning which drastically reduces cost and schedule. Several examples of these feeds are presented in this paper. © 2010 by the American Institute of Aeronautics and Astronautics, Inc. All rights reserved. Source


Clency L.-Y.,Custom Microwave Inc. | Scupin J.,Custom Microwave Inc. | Venezia P.,Custom Microwave Inc. | Califf T.,Custom Microwave Inc.
2010 IEEE International Symposium on Antennas and Propagation and CNC-USNC/URSI Radio Science Meeting - Leading the Wave, AP-S/URSI 2010 | Year: 2010

Custom Microwave Inc (CMI), uses a manufacturing technique known as electroforming along with precision microwave design CAD tools to integrate various components of a feed thereby achieving significantly smaller envelopes than is possible when using other manufacturing techniques. This integrated approach eliminates split joints and minimizes flange joints by integrating several components into single piece making it ideal for ultra low Passive Inter-Modulation (PIM) application. This approach also allows for high RF performance and higher power handling capability. A number of high performance feeds that CMI has produced for space application are presented to demonstrate the benefits of this integrated approach. © 2010 IEEE. Source


Clency L.-Y.,Custom Microwave Inc. | Scupin J.,Custom Microwave Inc. | Venezia P.,Custom Microwave Inc. | Califf T.,Custom Microwave Inc.
IEEE Antennas and Propagation Magazine | Year: 2010

Reflector antennas are widely used on satellites to communicate with ground stations. They simultaneously transmit and receive RF signals using separate downlink and uplink frequency bands. These antennas require compact and high-performance feed assemblies with small size, low mass, low passive intermodulation (PIM) products [1], low insertion loss, high power handling, and low cross-polar levels. The feeds must also be insensitive to large thermal variations, and must survive the launch environment. In order to achieve these desirable features without prototyping and/or bench tuning, Custom Microwave Inc. (CMI) has combined integrated RF design, precision CAD, and a precision manufacturing technique known as electroforming to closely integrate the various components of a feed or feed network, thereby achieving small size while maintaining high RF performance [2]. In addition to close integration, electroforming eliminates split joints and minimizes flanges by allowing several components to be realized in a single piece, making it the ideal manufacturing technique for ultra-low passive-intermodulation applications. This paper describes the use of precision design CAD tools along with electroforming to realize high-performance feed assemblies for various communication frequency bands for fixed satellite, broadcast satellite, and broadband satellite services. © 2010 IEEE. Source

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