MULTIBAND LARGE GROUND-BASED RADOME


APPLICATION:

Military. L, S, C-band radome for a large ground terminal for satellite operations.

CHALLENGE:

End customer wanted to modernize their satellite operations. The program required large, durable, low loss radomes for a new system design. Our customer asked us to produce a 8’ x18’ x 6” radome optimized for L-, S-, C-band frequencies and for losses of less than 0.5dB. The project included the design and fabrication of low weight access panels (8’x9’) and a cable conduit covers. Tooling costs needed to be optimized for a first article up to 4 more development units. Additionally the radome was required to withstand environmental conditions such as snow, wind and vibration.

SOLUTION

RWC designed, analyzed, tooled, painted and tested all the parts in-house. RWC fabricated significantly reduced cost tooling by moving away from a traditional machined billet tooling design and using non-machined metallic fabrication methodology, which still produced a fully consolidated and smooth surface finished part. Structural analysis and interfaces were heavily coordinated with the customer to meet the needs of all parties. The 8’ by 18’ long radome was manufactured of E-glass 7781 prepreg with foam core. Because of demanding environmental loading conditions, RWC custom designed highly loaded captive fastener hardware to enable quick removal and servicing of the unit in-field. Conduit cable covers were weight and cost optimized through utilizing commercial off-the-shelf G10/FR4 sheets.

The final part constitutes the largest radome Rock West has produced to date. The radome was tested in-house and performed as predicted by RWC’s insertion loss optimization analysis. This first deliverable has paved the way for a low-rate development program and maturity into a potential medium rate production program. RWC continues to work with the customer to make further improvements through their engineering development program.

KEY TAKEAWAYS

Adam Saunders, Program Manager, said, “We are excited about the manufacturing differentiators this program brings to our business and our ability to provide our customers the best value. As we do more large structures, we will continue to mature our tooling innovations and increase size constraints to provide cheaper and lighter large structural options for the market.”

Image shows two cable cover structures for the multiband large ground-based radome. The structures have tan interiors and white exteriors. They are placed on a table and a white background.
Image shows the radome tilted on a metallic stand in a large paint booth. The multiband large ground-based radome is painted white and in the center of the booth at an angle.
Image shows the radome tilted on a metallic stand in a large paint booth. The multiband large ground-based radome is painted white and in the center of the booth at an angle. The team who worked on the program is gathered in front and to the left side of the radome.