Engineering Capabilities - Proven Designs

RF Radome Design

MFG Galileo Composites is highly experienced in the science of determining the best radome construction for a given application and environment, taking into consideration the type and frequencies of the transmissions and the expected environmental loads. Past radome projects cover all frequencies from L Band through Ka Band and wind loads up to and exceeding 200 mph.

Our engineering staff, including a dedicated PhD-level radome design specialist, is practiced at listening to customers to fully understand the application and performance requirements. With the support of MFG Research, our team stays current on characteristics and applications of available resin systems, structural reinforcements and core materials such as structural foam and honeycomb. Each new radome design considers previous experience and currently available technologies.

The design process is an iterative process balancing the best optimization of RF requirements and structural loads such as wind speed. Once the minimum construction is established to meet the wind loads, the RF design process begins.

The elements of the RF design process include:

• Proven and proprietary computer algorithm is used to determine the predicted electrical performance of the radome:
  - Insertion loss (absorbed and reflected)
  - Sidelobe degradation
  - Boresight error
  - Phase delay
  - Others as needed
• Outstanding correlation between predictions and actual RF measurements
• Considers precise and empirically generated electrical material properties and layer by layer dimensions and variation
• Takes into account the precise geometrical relationship between the antenna and radome
• Considers the construction of the seams and optimizes for the specific frequency band
• Test panels can be produced and analysis results verified prior to production
• Analysis includes thickness sensitivity to ensure manufacturing variation is aligned with the RF analysis

RF Testing

MFG Galileo Composites uses an anechoic chamber to verify radome designs prior to beginning production as required by the customer.

• A test plan will be established by MFG Galileo Composites and provided to the customer for approval
• Testing may consider many parameters such as insertion loss, various incident angles, frequency, etc.
• Testing may be witnessed by the customer
• Full test reports provided

Structural Analysis - Best-in-Class FEA (finite element analysis)

• In-house finite element analysis (FEA) capability through MFG Research, a 60-year accredited research and analysis lab dedicated to supporting the business entities of Molded Fiber Glass Companies.
• Registered Professional Engineers
• Analysis trcharacterization studies on all radome materials to support analysis results:
  - All radomes are analyzed using a finite element analysis (FEA) approach
  - The analysis takes into account the ply-by-ply orthogonal characteristics of composite structures
  - Typical loads include wind speeds, seismic, snow/ice, etc.
  - All material properties have been empirically created and used as analysis inputs

Mechanical Design

• CAD software used to design all radomes, reflectors and other projects
• For radomes, the antenna is precisely modeled inside the radome to ensure proper fit during installation
• CAD design is used as the input to the FEA and RF analysis ensuring accuracy and continuity across all aspects of the design and analysis process
• Capability to design and analyze drive systems, mechanisms, accessories, etc. as they relate to our radomes and reflectors

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