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This paper discusses the design, analysis, and development of a large Ka-band slot array for digital beam-forming application. The array consists of 160 times 160 elements in 16 subarrays for producing 16 digital beams in the receive mode. Infinite array mutual coupling model has been employed in the design and analysis models. Challenges posed in meeting the pattern and return loss specifications because of manufacturing tolerances are discussed. Measured return loss and pattern characteristics of 10 times 40 slot array modules as well as results on a 1 m times 1 m demonstration array are presented.