Design of Septum Polarizer Waveguide Feed Manufactured by Split-Block Technique

A design method for the split-block manufacturing technique of the septum polarizer is proposed. By reasonably adjusting the splitting position of the septum polarizer, the negative influence on the circularly polarized (CP) performance caused by the misalignment and welding will be effectively reduced. Two split-block models of the septum polarizer are built for comparison and the effects of the misalignment and welding are analyzed for both of the two models. Finally, the septum polarizer is designed, machined, and welded with minimal impact on the CP performance. A conical horn antenna is connected with the septum polarizer. Good agreement can be found between the simulated and measured results, which confirms that the manufacturing technique is worth considering.