Integration of ultrasonic consolidation and direct-write to fabricate a miniature synthetic aperture radar (SAR) phased array antenna

A research project was undertaken to utilize Ultrasonic Consolidation (UC) and Direct-write (DW) to fabricate an advanced miniature synthetic aperture radar (SAR) antenna. This research necessitated fundamental research relating to the processes of UC and DW. The design of an enclosure for the SAR antenna was desired that could minimize the losses due to misalignment and other issues while decreasing the mass compared to current systems. In order to develop such a design there were numerous tests that needed to be performed for both DW and UC. The results from the testing as well as the general design of the SAR antenna formulate a base for design guidelines to be built upon in the future. The successful fabrication of a prototype SAR enclosure demonstrates the usefulness of UC and DW as well as the validity of the design parameters determined through testing.