Additively manufactured antenna with Vivaldi element

A method of fabricating an antenna assembly, the method comprising:

• additively manufacturing a feed block having an opening therein and a tapered feed slot extending from the opening to an outer periphery of the feed block, the tapered feed slot being adjacent to a first flare arm and a second flare arm;
• and
• additively manufacturing a feed line having a first portion integral with the feed block as a contiguous unitary component, and a second portion at least partially extending across the tapered feed slot,
• wherein the tapered feed slot is continuously tapered with respect to at least one of the first flare arm and the second flare arm;
• and
• wherein the feed block includes a first channel configured to receive a portion of the first flare arm and a second channel configured to receive a portion of the second flare arm.

An antenna array assembly comprising:

• a plurality of antenna assemblies arranged in an array, each of the antenna assemblies including a first flare arm;
• a second flare arm located adjacent to the first flare arm;
• a feed block having an opening therein;
• a feed slot extending from the opening to an outer periphery of the feed block;
• and
• a feed line having a first portion integral with the feed block as a contiguous unitary component, and a second portion at least partially extending across the feed slot;
• wherein the feed block includes a first channel configured to receive a portion of the first flare arm and a second channel configured to receive a portion of the second flare arm.