[GHz] range of RF in which most of our potential customers operate,” says Cathey.
Manufacturing antenna systems via conventional methods such as brazing and plunge EDM is a complex, multistage process that can take an average of eight months of development time and three to six more of build time, says Optisys COO Robert Smith, M.E.
“Our unique offering is that we redesign everything from an additive manufacturing perspective,” says Smith. “We take into account the entire system functionality, combine many parts into one, and reduce both development and manufacturing lead times to just a few weeks. The result is radically improved size and weight at lower costs.”
Optisys conducted a profitability analysis on how their redesigned microwave antennae test piece compared to a legacy design that is traditionally manufactured. By optimizing their design for additive manufacturing, Optisys realized the following benefits:
- Part count reduction from 100 discrete pieces to a 1 piece integrated assembly
- Weight savings of over 95%
- Lead time reduced from 11 months to 2 months
- Production costs reduced by 20-25%
- Non-recurring costs reduced by 75%
Other advantages of 3D printing
“In addition to what our test-piece project revealed, 3D printing offers a number of other advantages,” says Smith. “When we design multiple antenna components into a single part, we reduce the overall insertion loss of the combined parts. And because our antennas are so much smaller this also lowers insertion loss dramatically despite the higher surface roughness of AM build, for similar or even better RF performance than conventional assemblies.”
Optisys can print in a variety of metals with its Concept Laser machine, though for antenna products they prefer aluminum because of its surface conductivity, light weight, corrosion resistance and strength under shock and vibration. “3D-printed metal will have virtually the same properties as a solid piece of the same material for RF performance,” says Smith. “Structurally the products have been tested in rigorous vibration environments and they also have the same coefficient of thermal expansion (CTE) as wrought metals. This also gives them better stability over temperature than plastic RF components.”
Part consolidation through AM provides a number of downstream benefits as well, Smith says. “Reducing part count also reduces assembly and rework. It’s easy to add features to an existing AM design, easier to assemble the finished components and, long-term, you have less testing, maintenance and service when you have fewer parts.”
The Optisys team has a combined 60 years of aerospace experience in SATCOM (satellite communications), RF design, LOS (Line-of-Sight) communications and Mechanical Design. “We’ve spent years on parameter and process development of our antenna-system optimization technology package,” says Cathey. “We validate our designs through simulation, test to all aerospace frequencies, and manufacture military-ruggedized production parts.” The company has a number of patents pending and is in discussions with leading aerospace companies and academic institutions about expanding its portfolio of product lines.
Optisys develops system-optimized microwave antennas for commercial, aerospace and defense applications using metal 3D printing. A full-service design, simulation, engineering and manufacturing company, Optisys specializes in applying additive manufacturing (AM) to provide greatly reduced size, weight, lead times and improved reliability by creating structures not possible in the past. For more information go to https://www.optisys.tech/ or call (+1) 801-664-5595.
About Concept Laser
Concept Laser GmbH is one of the world’s leading providers of machine and plant technology for the 3D printing of metal components. Founded by Frank Herzog in 2000, the patented LaserCUSING® process – powder-bed-based laser melting of metals – opens up new freedom to configuring components and also permits the tool-free, economic fabrication of highly complex parts in fairly small batch sizes.
Concept Laser serves various industries, ranging from medical, dental, aerospace, toolmaking and mold construction, automotive and jewelry. Concept Laser machines are compatible with a diverse set of powder materials, such as stainless steel and hot-work steels, aluminum and titanium alloys, as well as precious metals for jewelry and dental applications.
Concept Laser Inc. is headquartered in Grapevine, Texas and is a US-based wholly owned subsidiary of Concept Laser GmbH. For more information, visit our website at www.conceptlaserinc.com
LaserCUSING® is a registered trademark of Concept Laser.
Joyce Yeung, Director of Marketing, Concept Laser
Phone: (817) 328-6500
Phone: (801) 664-5595