3-D printed waveguide-fed X-Band helix antenna array

The use of 3-D printing and plating of thermoplastics can be a cost-effective technique in rapid prototyping of antennas. A waveguide-fed helix antenna array operating at X-Band was designed in support of the RF Telecommunications Subsystem of NASA's Europa Mission. The antenna is made up of three identical helices, a waveguide bottom with inductive irises, waveguide flange and a waveguide lid with cylindrical isolation cups. In order to assess relative performance of the 3-D fabrication process, three antenna prototypes were made. The first build completely 3-D printed the antenna, the second build partially 3-D printed the antenna and the third build used conventional metal machining. The principal plane cuts for all three antennas were measured in a compact range and the results are compared with each other and with simulated performance.