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An Additively Manufactured, All-metallic Frequency-scaled Ultra-wide Spectrum Element (AM-FUSE) Active Electronically Scanned Array (AESA) for Space-borne Applications

A new breed of the Frequency-scaled, Ultra-wide Spectrum Element (FUSE) is built entirely from a single piece of metal using direct metal laser sintering (DMLS) for space-borne missions. An active electronically scanned array (AESA) was built that includes an 8×4 linearly polarized aperture and low-profile feed circuitry that has eight true-time delay units (TDU) to fit inside a 3U CubeSat. This AESA operates over 1.5 GHz – 6 GHz, scanning +/- 45 degrees in azimuth with a very low active voltage standing wave ratio (active VSWR). The weight of the array with its combiner and beamforming boards is less than 3 lbs.