Complex RF Assemblies | Optisys Monolithic Waveguide & Filters

Complex & Unique RF

Components

With deep experience in both RF design and additive manufacturing, Optisys has become particularly adept at delivering complex RF assemblies and sub-assemblies for demanding space and aerospace applications. These assemblies can include switches, diplexers and combiners, waveguide runs, filter banks, thermal features such as integrated heat sinks, and other RF and mechanical elements that traditionally require multiple discrete parts and assembly steps. By designing these systems holistically, Optisys is able to control RF performance, mechanical interfaces, and thermal behavior simultaneously.

The true value of this approach lies in combining multiple RF and mechanical components into a single, additively manufactured structure, reducing part count, mass, assembly risk, and integration complexity. At the same time, Optisys has delivered highly tailored solutions for unique customer challenges—such as filter banks designed to fit within strict volume constraints or tightly integrated waveguide assemblies optimized for specific system architectures. These RF assemblies are production-proven, with designs currently operating in space, supporting lunar missions, and flying across multiple orbital regimes.

Key Benefits

Integration of multiple RF and mechanical functions into monolithic assemblies
Significant SWaP reduction compared to traditional multi-piece designs
Complex internal waveguide and filter geometries enabled by additive manufacturing
Improved repeatability and unit-to-unit consistency
Reduced assembly, alignment, and supply-chain risk
Proven heritage with systems flown in space, lunar, and multi-orbit applications

Key Takeaways

Additive manufacturing enables Optisys to integrate complex RF assemblies into compact, repeatable, flight-proven structures that reduce risk, mass, and system complexity.

Why Additive Manufacturing Matters Here

Complex RF assemblies demand precise control of internal geometry, RF interfaces, and mechanical integration—requirements that push beyond the limits of traditional manufacturing. Additive manufacturing allows Optisys to consolidate switches, waveguide routing, filter banks, thermal features, and mounting interfaces into monolithic structures with tightly controlled RF paths. This eliminates assembly-driven variability, reduces part count and mass, and improves overall robustness.

Just as importantly, additive manufacturing enables Optisys to solve highly constrained integration problems—such as fitting high-performance RF assemblies into limited volumes—without compromising RF performance. The result is repeatable, production-ready RF assemblies with proven space and lunar heritage.

Optisys designs are covered by one or more patents.

Commercial Off-The-Shelf

Looking for a proven solution with low or no NRE and fast turnaround? Optisys offers a growing library of flight-proven antenna designs that can be configured and delivered quickly.

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Custom Solution

Have requirements that don’t fit any standard product? Custom antenna design has been core to Optisys since day one, enabling performance, SWaP, and integration targets others can’t meet.

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