Machined Metal FUSE Array Apertures

A Frequency-scaled Ultra-wide Spectrum Element (FUSE) antenna aperture is presented that is readily produced as size-scalable modular sub-array tiles via conventional (subtractive) machining of common metal stock, similar to the manufacturing of wideband all-metal Vivaldi flares. Like the Planar Ultra-wideband Modular Antenna (PUMA) array, whose modular aperture production can be automated via commercial printed circuit board (PCB) manufacturing at minimal touch labor, these FUSE apertures can be produced with quick turnaround time at rapid prototyping metal machining shops. The radiator can also be produced via additive manufacturing (3D printing), making this simple design an excellent choice for benchmarking alternative manufacturing techniques. This low-profile ultra-wideband array aperture demonstrates operation from 5 GHz to 21 GHz (4.2:1 VSWR bandwidth), with Voltage Standing Wave Ratios (VSWR) below 2.0 for 45-degree scans in all planes (60-degree scan VSWR <; 2.0, except H-plane scan VSWR <; 3.0) at optimal lattice spacing. Measured results are presented to validate modeling predictions.