Systems and methods for injection molded phase shifter

A method for fabricating a phase shifter, the method comprising:

• fabricating a ferrite element with a first end and a second end, wherein electromagnetic energy propagating through the ferrite element propagates between the first end and the second end;
• placing the ferrite element within a waveguide mold;
• injecting a liquefied dielectric into the waveguide mold, wherein the liquefied dielectric hardens to form a first solid dielectric layer and a second solid dielectric layer that abut against out-of-plane surfaces of the ferrite element, wherein the first solid dielectric layer and the second solid dielectric layer have a first dielectric end that corresponds to the first end and a second dielectric end that corresponds to the second end, wherein the injected dielectric forms a first coupling section and a second coupling section, wherein the first coupling section and a second coupling section are respectively connected to the first dielectric end and the second dielectric end as a contiguous piece of dielectric;
• exposing in-plane surfaces of the ferrite element, wherein the in-plane surfaces extend longitudinally between the first end and the second end and are orthogonal to the out-of-plane surfaces that extend longitudinally between the first end and the second end;
• masking surfaces through which electromagnetic energy is emitted into and transmitted from the phase shifter;
• and
• plating the exposed surfaces of the phase shifter.

A phased array antenna system, the system comprising:

• a plurality of waveguide elements configured to emit electromagnetic radiation;
• a plurality of phase shifters, a phase shifter in the plurality of phase shifters coupled to an associated waveguide element in the plurality of waveguide elements, wherein the phase shifter changes the phase of the electromagnetic radiation to steer an antenna beam, the phase shifter comprising:
• a ferrite element configured to propagate electromagnetic energy between a first end and a second end, wherein the ferrite element has two in-plane surfaces and two out-of-plane surfaces, wherein the in-plane surfaces are opposite one another and extend longitudinally between the first end and the second end, and the out-of-plane surfaces are opposite one another and extend longitudinally between the first end and the second end, wherein the out-of-plane surfaces are orthogonal to the in-plane surfaces;
• a first solid dielectric layer that abuts against one of the out-of-plane surfaces of the ferrite element;
• a second solid dielectric layer that abuts against one of the out-of-plane surfaces of the ferrite element, wherein the first solid dielectric layer and the second solid dielectric layer abut against opposite surfaces of the ferrite element;
• and
• a metal layer encapsulating the ferrite element, the first solid dielectric layer, and the second solid dielectric layer, wherein the metal layer is in contact with the two in-plane surfaces of the ferrite element;
• a first coupling section;
• and
• a second coupling section, wherein the first coupling section and the second coupling section are respectively connected to the first dielectric end and the second dielectric end;
• and
• wherein the first coupling section, the second coupling section, the first solid dielectric layer, and the second dielectric layer are a contiguous piece of dielectric.
• a plurality of magnetizing windings, wherein each magnetizing winding in the plurality of magnetizing windings changes the magnetization of the ferrite element in an associated phase shifter.