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This paper presents the design and analysis of large Focal Plane Arrays (FPA) of thick Taper Slot Antennas (TSA). This communication extends the application of fast numerical method based on Macro Basis Functions (MBF) produced by Array Scanning Method (ASM) to the simulation of planar array of 3D Vivaldi antennas. This simulation technique is validated through the comparison with the brute force solution of a planar array containing 31 thick bowtie antennas. We also studied an array of 71 thick Vivaldi antennas in which we investigated the truncation effects at the array borders. Finally, the manufacturing feasibility of this type of thick Vivaldi antennas is verified by the development and measurement of an array of 4 thick metal only Taper Slot Antennas.