Manufacturing challenges for a W-band laminated waveguide phased array

This paper describes the manufacturing challenges of a specific design over 90 GHz with an eye toward meeting performance goals while fitting into a production environment. Understanding the critical physical dimensions, along with the non-critical allowed for a successful design demonstration. Furthermore, this paper will illustrate the specific tactics utilized for a successful design showing both material property measurements and process developments needed to execute a multi-element array applicable to W-band applications.