Compact and Reliable T/R Module Prototype for Advanced Space Active Electronically Steerable Antenna in 3-D LTCC Technology

The aim of this paper is to present a novel and compact transmit/receive module (TRM) for enhancing antenna performances to be employed in space applications. The key advancement is the use of a 3-D technology which, to the best of our knowledge, would be for the first time introduced in the space industry for hermetically packaging RF modules. The 3-D module development is based on the highly demanding specifications of space active electronically steerable antennas (AESAs); the TRM consists of two 'submodules' electrically connected by an ad hoc interposer. The complete electrical design process, together with a comprehensive discussion on electromagnetic, mechanical, and thermal aspects, is presented, and the achieved module performances such as gain and return losses are detailed. Moreover, several manufactured samples are measured to validate the simulated design, and the excellent results in terms of gain, noise figure, and output power fulfilling the target specs are presented and discussed. The presented data, characterized by a limited variability among the 10 measured samples, make the proposed design and the manufacturing process a good candidate in terms of potential reliability for building the next generation of high-performance space AESA.