SATELLITE DATALINK 2.4 METER DIMENSIONALLY TUNABLE REFLECTOR


APPLICATION:

Commercial. Dimensionally tunable precision reflector for a space datalink application.

PREVIOUS LIMITING TECHNOLOGY:

Previous ultra-precision reflectors (RMS <0.003”) have been cost prohibitive for much of the commercial sector. By creating a design with sections that are discretely deformed utilizing an active backing structure, this dish can optimize its shape and RF performance while meeting more constrained cost targets.

CHALLENGE:

The customer requested a large (2.4 meter) reflector with a high degree of accuracy (RMS target of <0.003”). Additionally the reflector also required a back-up structure than enabled a deformable design through the use of an active tensegrity structure utilizing titanium-composite struts to achieve the correct shape adjustments. This objective was to optimize performance with both a high precision molded surface but also self-adjust to correct effects due to thermal and atmospheric conditions.

SOLUTION

Rock West utilized high accuracy monolithic graphite tooling and a hybrid composite sandwich design to balance stiffness and deformability requirements. This sandwich structure was then augmented with a carbon fiber composite isometric grid attaching at discreet attachment nodes. The reflector surface is treated with a conductive paint applied with high accuracy. The results were a measured 65.2 dB gain vs. baseline/target of 57.7 dB.

Finished deformable reflector laying on a white paper surface for photography. The interior of the dish is painted a tan color, and the backing structure is visible, including attached nodes and connecting carbon fiber tubes.
Image shows the underside of the deformable reflector. It is a closeup image of the center insert, a metallic component with spokes. There are small carbon fiber tubes extending outward from the exterior surface of the component. The carbon fiber surface of the back of the reflector is visible.
Image shows the inside of the precision reflector dish. The interior of the dish is painted a tan color. Image shows the center metallic component that has spokes. There are 3 small rectangular cutouts on the surface of the dish radiating from the center.
Megalodon dimensionally tunable reflector is deployed in the field. Hardware is on a rooftop, and there is a blue sky and mountains in the distance. The reflector is attached to a large column with electronics equipment and wiring visible. The image view is looking at the back of the reflector with the deformation grid.
Megalodon dimensionally tunable reflector is deployed in the field. Hardware is on a rooftop, and there is a blue sky and mountains in the distance. The reflector is attached to a large column with electronics equipment and wiring visible. The image view is looking at the side of the reflector with interior of the dish and the edge of the deformation grid visible.
Megalodon dimensionally tunable reflector is deployed in the field. Hardware is on a rooftop, and there is a blue sky and bright sun above. Three technicians are working around the structure. The reflector dish is attached to a large column and is directed up at the sky, with electronics equipment and wiring visible.