Low Cost Additively Manufactured Antenna Array Modules

This paper introduces a modular, end-fire, dual- polarized ultra-wideband scalable array (MEDUSA) realized with stereolithography (SLA) to achieve a novel connector-less phased array radiating element. The radiator is based on a variation of conventional tapered slot antennas (i.e. Vivaldi) where a new integrated balun approach is described which leverages the flexibility provided by additive manufacturing (AM). The design further achieves a fully-monolithic element consisting of RF coaxial interface, balun, and free-space transformer. This effectively eliminates the need for additional RF connectors in order to minimize phased array antenna costs. Simulations (2-20 GHz) demonstrate MEDUSA performance to be comparable with conventional Vivaldi arrays. A finite 8×8 array covering 2-20 GHz has been prototyped and measured to demonstrate agreement in active impedance and element patterns.