On the development of Antenna feed array for space applications by additive manufacturing technique

Space agencies are looking for advanced technologies to build light weight and stiff payload components to bear space environment and launch loads. Additive manufacturing (AM) techniques like Direct Metal Laser Sintering (DMLS) is one of the suitable option which can be explored for space applications. This paper highlights the development process of Antenna Feed Array (AFA) using DMLS as an Additive Manufacturing (AM) technique. A high efficiency horn element is used in the array. Such horns are preferred for this development as they are the prime choice for feed elements in High Throughput satellites (HTS) that employ Multibeam Antennas. A brief description of Multibeam antennas along with the RF design process for the high efficiency horn is presented. In the development process, certain design rules of AM are adopted based on consideration to produce self-sustaining structures. AFA realized by DMLS is evaluated by functional testing, vibration testing for space qualification test levels. Test results shows its structural intactness which proves its space worthiness. Procedures are very well established for further development of space payload components.