An innovative approach to cost effective superplastic forming of precision MMW components on production quantities

Current fabrication techniques for millimeter wave (MMW) waveguide assemblies are inherently costly and poorly suited to realizing economies of scale. Improved processes for manufacturing these components at reasonable costs are required to exploit recent advances in MMW technology. In this project we will develop and demonstrate an innovative superplastic forming (SPF) production process for the lost cost fabrication of MMW planar waveguide assemblies. We expect the process to realize superior feature definition, sharp corners, and tight tolerances and be well suited to high volume production applications. In Phase I we will develop the critical process parameters and demonstrate feasibility of our innovative process by fabricating a number of test pieces suitable for measuring feature definition, tolerances, and surface finishes. A comprehensive producibility analysis will be prepared based on the results of these experiments. In Phase II we will develop the detailed production processes and component design guidelines, and establish a pilot production capability. Commercialization of this technology, either through a spin-off company or through licensing, will occur in Phase III.