Additively manufactured antenna system for near earth and deep space applications

A process for fabricating an antenna system for near Earth and Deep Space applications, the process comprising:

• additively manufacturing an aluminum alloy powder feedstock on a build plate at a 45-degree angle to form a monolithic choke ring horn antenna and a septum polarizer system and one or more tensile coupons layer by layer, wherein the one or more tensile coupons are coupled to the build plate and the monolithic choke ring horn antenna and the septum polarizer system;
• exposing the monolithic choke ring horn antenna and the septum polarizer system and the one or more tensile coupons on the build plate to a heat treatment process by heating the monolithic choke ring horn antenna and the septum polarizer system and the one or more tensile coupons on the build plate at an elevated temperature for a first period of time to form a solid solution of magnesium and silicon in the aluminum alloy followed by aging at a lower temperature than the elevated temperature for a second period of time to form ordered arrays of atoms in the aluminum alloy;
• removing the tensile coupons from the build plate and the monolithic choke ring horn antenna and the septum polarizer system;
• coating nickel onto surfaces of the monolithic choke ring horn antenna and of the septum polarizer system at a thickness to reduce surface roughness;
• and
• coating gold onto the nickel coating at a thickness to reduce radiofrequency loss when in use.