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Contact

Service@optisys.tech

801-664-5595

Address

6764 Airport Rd
West Jordan, UT 84084

COPYRIGHT © 2019 OPTISYS.  ALL RIGHTS RESERVED

FREQUENCY BANDS

We have experience designing in frequency bands ranging from 10 MHz to 110 GHz. We can optimize your systems in the following bands to have the lightest weight and highest performance possible, in LOS (Line of Sight) or SATCOM applications.

  • L-band (1.0 - 2.0 GHz)

  • S-band (2.0 - 4.0 GHz)

  • C-band (4.0 - 8.0 GHz)

  • X-band (8.0 - 12 GHz)

  • Ku-band (12 - 18 GHz)

  • K-band (18 - 27 GHz)

  • Ka-band (27 - 40 GHz)

  • Q-band (33 - 50 GHz)

  • V-band (50 - 75 GHz)

  • E-band (60 - 90 GHz)

  • W-band (75 - 110 GHz)

  • SATCOM X-band (7.25-7.75, 7.9-8.4 GHz) 

  • SATCOM Ku-band (10.95 - 12.75, 13.75 - 14.5 GHz)

  • SATCOM Ka-band (20.2 - 21.2, 30.0 - 31.0, 17.7 - 20.2, 27.5 - 30.0 GHz)

WAVEGUIDE SIZES

  • X-band (WR 75, WR 90, WR 112)

  • Ku-band (WR 51, WR 62, WR 75)

  • K-band (WR 34, WR 42)

  • Ka-band (WR 28, WR 34)

  • Q-band (WR 22, WR 28)

  • V-band (WR 19, WR 15)

  • E-band (WR 15, WR 12)

TYPICAL LEAD TIMES

3D printing allows for quick lead times for our RF products. We can typically design a part and have a functional prototype in 6 - 8 weeks.  Changing the design or adding features are very easy and we can re-print the product in a couple days.  For example, changing the interface type (waveguide, coaxial, etc) or location, or modifying mounting features to accommodate a design change.

SURFACE FINISH

The surface finish of 3D metal printed waveguide has higher roughness than a polished metal surface. This leads to slightly more loss per length, which is partially overcome by the significantly reduced total length. This means that by letting us design multiple antenna components into a single part, we can reduce the total loss of all the parts combined, resulting in less loss at the system level compared to standard manufacturing practices.

Another major reason for lower loss on our systems is the removal of seams on the internal walls of waveguides in a typical CNC-machined waveguide part.  These seams actually add a significant contribution to the loss of the part.

 

Surfaces that need to be polished can be tooled to create a smooth finish.

Here is a good article.
http://www.microwaves101.com/encyclopedias/waveguide-construction

RF PERFORMANCE

Our 3D printing process can maintain the tight tolerances necessary for operation of low-loss RF components up to 110 GHz, with high part-to-part precision. This allows for high consistency from one printed part to the next. We will design, test, and verify the RF performance of the 3D printed parts we fabricate so that you know every system will work.

RF COMPONENTS

We can 3D print any standard RF components for your system. Including: Diplexers, Filters, Phase shifters, Waveguides, Tees, Combiners, Couplers, Polarizers, Feeds, etc.  It is better to design a combined system of these pieces without creating unnecessary seams that effect RF performance.

MATERIAL PROPERTIES

3D printed metal will have vitually the same properties as a solid piece of the same material for RF performace. Structurally, they have been tested in rigorous vibration environments and can be designed to withstand them as well as any other metal.

 

A 3D printed object is not porous, it is a solid.  It can be tooled to a smooth finish if needed.  ​

We can print in multiple metals including: Aluminum, titanium, stainless steel, hardened tool steel, and cobalt chrome. We prefer to use aluminum on most of the antenna products because it is light weight, corrosion resistant, and has good strength for shock and vibration.

The Coefficient of Thermal Expansion (CTE) will also be the same as with wrought metals resulting in better stability over temperature than plastic RF components.

BEST USES FOR 3D METAL PRINTING

  • Reducing weight.

  • Reducing size/volume.

  • Increasing system performance.

  • Integrating multiple parts.

  • Reduce touch labor for assembly and rework.

  • Great for high mix/low volume products like custom antennas.

  • No tooling needed for design iterations.

  • Great for qualification or MVP (Minimum Viable Product) validation.

  • Design flexibility allows for shapes that are impossible with another process.

  • Parts that are not available because of DMS (diminished vendor sourcing).

  • Reducing inventory costs by only printing what is needed.

  • Thermal dissipation designed into objects (Forced convection, natural convection, conduction, and radiation).

  • Designing parts specifically for 3D printing currently is best from 1 GHz to 110 GHz.

REDUCING "SWaP"

One key advantage of 3D metal printing is "SWaP" (Size, Weight, and Power) reduction.  We will design your system to greatly reduce the number of components, connections, waveguide length, and weight of the system.  We can print virtually any internal or external geometries without needing to cut the product into multiple parts.  For example, we designed a four port monopulse comparator in a single printed component which weighed 12 ounces.  A representative part made from machining/braising/casting would weigh 2 to 7 pounds and require 10 to 20 waveguide pieces.  This link is an example of a brazed monopulse comparator.  

http://www.sylatech.com/microwave-products/monopulse-comparators

PRINTING PROCESS

3D metal printing is known by many names.  Additive Manufacturing (AM), Laser Powder Bed Fusion (L-PBF), Direct Metal Laser Sintering (DMLS), and Selective Laser Melting (SLM) are some of the common terms.

COST SAVINGS with 3D METAL PRINTING

  • Reduce non-recurring costs

    • Less engineering time with highly customized designs.

    • Reduce time by implementing Design For Manufacturability/Assembly (DFMA) into the product.

  • ​Reduce recurring costs

    • Reduce part count reduces assembly and rework.

    • Easy to add features to existing design.

    • Lower testing, maintenance, and service for fewer parts.

    • Design for ease of assembly.

  • Reduce extremely expensive processes such as EDM (Electrical Discharge Machining).
  • Lower inventory costs.

  • Weight reduction lowers the systems costs, the system can use smaller components.

ITAR Registration

  • Optisys is ITAR registered to be able to work on classified programs when required.

Other Questions

Is there something you’re still looking for? Please reach out and we’ll get back as soon as possible.