Additively Manufactured Embedded Antennas in High Temperature Composites

Physical Sciences Inc. (PSI) will design and manufacture a functional antenna at a relevant RF band, embedded in the surface of a high temperature composite to enable advanced guidance and control in vehicles such as the Common Hypersonic Glide Body (CHGB). ÝPSIís approach integrates its high rate prepreg tape braiding (PTB) process for manufacturing extreme environment aersoshell structures with Direct Write (DW) of high temperature metals and dielectrics to provide an affordable production solution for these high performance systems. ÝPhase I feasibility will be demonstrated by embedding, via DW, antennas in both flat and cylindrical high temperature composites manufactured via PTB. ÝResults from evaluation of the embedded antennas will verify performance of the system and thereby validate the integrated manufacturing approach. In Phase 2 (P2), an antenna will be embedded in a more complex aeroshell geometry, and RF functionality measured to increase the TRL and MRL. ÝMaterial and process optimization of the antenna will be completed prior to the manufacture of multiple aeroshells with embedded antennas to show accuracy and repeatability of the process as well as demonstrate reductions in the process time and manufacturing cost. ÝRF Testing of an antenna embedded in an aeroshell structure, at both room and elevated temperature, will close out the P2 Project.