Process for fabricating a three dimensional molded feed structure

A process for fabricating a three dimensional radio frequency (RF) antenna structure, the process comprising:

• providing a flexible circuit substrate;
• forming a first preselected pattern of channels in the flexible circuit substrate;
• depositing a conductive layer on the formed flexible substrate;
• and
• removing portions of the conductive layer to form a plurality of conductive traces,
• wherein the forming the first preselected pattern of channels in the flexible circuit substrate comprises:
• placing the flexible substrate on a precision die comprising the first preselected pattern of channels;
• pressing the flexible substrate into the precision die using an elastomeric material thereby sandwiching the flexible substrate between the elastomeric material and the precision die;
• and
• applying heat to the flexible substrate sandwiched between the elastomeric material and the precision die.

A process for fabricating a three dimensional radio frequency (RF) antenna structure, the process comprising:

• providing a flexible circuit substrate;
• placing the flexible substrate on a precision die comprising a first preselected pattern of channels;
• pressing the flexible substrate into the precision die using an elastomeric material thereby sandwiching the flexible substrate between the elastomeric material and the precision die to form the first preselected pattern of channels in the flexible substrate;
• depositing a conductive layer on the formed flexible substrate having the first preselected pattern of channels after forming the first preselected pattern of channels in the flexible circuit substrate;
• and
• removing portions of the conductive layer to form a plurality of conductive traces.