13.04.2021

TESAT - RF (ESA)

Further Development of Existing RF Antenna Components Using Additive Manufacturing Development of a single part integrating waveguide filter, bends, coupler, and supporting structures using additive manufacturing. On behalf of the European Space Agency (ESA), the consortium leader and end user TESAT Spacecom GmbH & Co. KG and the consortium partners Lithoz GmbH, Kiel University, and FOTEC Forschungs- und Technologietransfer GmbH are working on the further development of existing RF antenna components for telecommunications satellites using additive manufacturing.

FOTEC Forschungs- und Technologietransfer GmbH

Background

Two concepts were selected for redesign, always taking into account the geometric possibilities offered by additive manufacturing. Specifically, these are filter housings for different frequency bands, C-band and Ku-band. In both cases, optimization potential regarding technical performance and cost was identified, and a manufacturing strategy was developed. A special feature of this project is the combination of two additive manufacturing processes in one component (C-band filter). While the housing was manufactured by FOTEC, the necessary ceramic filters came from Lithoz in Vienna. Lithoz uses a stereolithography-based system to build technical ceramics such as aluminum oxide layer by layer. The possibilities for increasing electrical performance were simulated by Kiel University, and the geometries were adjusted accordingly. In the second concept (Ka-band waveguide), a 4-channel component was monolithically built and significantly improved through topology optimization; mechanical stability and weight are now at a very good level. The electrical measurements of the components are carried out at TESAT, where the simulation results from Kiel University are also checked, and the model is verified accordingly.

Currently, the complex internal channels of antenna components are painstakingly manufactured using milled segments, which are then screwed together. This process introduces numerous potential sources of error, such as at the joints and flanges, negatively impacting electrical performance and signal stability. Furthermore, the comparatively high weight and assembly effort of such products increase the overall mass of the satellite, resulting in additional costs. Therefore, evaluating new manufacturing methods is the next logical step.

Objectives

Additive manufacturing of C- and Ka-band filter housings
Cost, time, and weight reduction of production-ready antenna components
Combination of two additive manufacturing processes in a single component
Evaluation of electrical performance and cost-effectiveness compared to conventional products

Results

Project ongoing