Modern commercial and military sensors require low cost, robust antennas. We propose to fully develop a low-cost, low to medium volume production method using printed circuit technology to fabricate arrays of conformal waveguide antennas. The goals will be to advance the state of art for this fabrication method by building more complex antennas. Than ever before, adding components to make the technology more compatible with existing hardware and incorporating additional circuitry into the antenna using compatible fabrication methods. Antennas will be fabricated for military fuse and seeker applications but related applications in the commercial sector will also be investigated. During the Phase I effort we identified various technologies that could be used to fabricate low-cost waveguide antennas for use in severe environments. The best fabrication methods was determined to be a photochemical milling process based on printed circuit technology that provides high accuracy in milling thin metal sheets at low cost. The metal sheets are then formed into the desired waveguide shape by folding and locked with alignment tabs. Since this fabrication method is new we propose to fabricate more complex structured and develop additional components so that the process can be refined and perfected and brought closer to everyday use. The result of this work will be a well defined antenna manufacturing process that can be used to fabricate antennas for commercial applications such as automobile collision avoidance radar and intelligent highway information systems and for military applications such as slotted waveguide radar antennas, and seeker and fuse antennas.
Keywords: Low-Cost Manufacturing Waveguide Circuits Conformal Waveguide Waveguide Arrays Waveguide Fabrication
