CAD/CAM for development and fabrication of cosecant reflector antennas

The application of CAD/CAM techniques to lower the cost of redesigning and manufacturing specialized cosecant reflector antennas for use in the mm-wave range is described and demonstrated. Consideration is given to the theoretical computation of reflector surfaces; the representation of a reflector surface in a CAD system; the numerically controlled milling of an Al, wood, or plastic model antenna; and the construction of the antenna (by spraying the 300-micron Sn-alloy conducting layer onto the coated model surface and then applying a 1-mm-thick epoxy-matrix GFRP layer, a 20-30-mm layer of flexible polyurethane foam, and a final GFRP layer). Diagrams and photographs are provided.