Frequently Asked Questions
Optisys is an antenna and RF design company that leverages the benefits of additive manufacturing to achieve exceptional performance, tightly integrated solutions, and significant SWaP-C savings. We use additive manufacturing not as a production method, but as a design enabler
Optisys has been around for over ten years and has heritage in terrestrial, aerospace and space applications with multiple antennas and RF systems in multiple orbits.
We primarily work with aerospace-grade aluminum alloys. Material selection is driven by performance, environmental, and program requirements, and we use qualified alloys that are well-characterized for strength, thermal stability, and repeatability.
3D printed metal has virtually the same properties as a solid piece of the same material. Structurally, our designs have been tested in rigorous vibration environments and have proven to provide the same strength and rigidity as a machined part.
Just like something machined from stock 6061 aluminum, an object printed via Powered Bed Fusion it is a solid and can be machined and tooled as needed.
We can print in multiple metals including: aluminum, titanium, stainless steel, hardened tool steel, and cobalt chrome. We use aluminum on most of antenna products because it is lightweight, corrosion resistant, and has good strength for shock and vibration.
The Coefficient of Thermal Expansion (CTE) will also be the same as with wrought metals resulting in better stability over temperature than plastic RF components
We select the additive manufacturing process that best fits the application. While we support several 3D-printing technologies in-house. Our primary production method is Powder Bed Fusion, which allows us to achieve the tight tolerances, complex geometries, weight reduction and RF performance our applications require.
One key advantage of additive manufacturing is significant size and weight reduction. We will design your system to greatly reduce the number of components, connections, waveguide length, and general weight of the system. We can print very intricate geometries without needing to cut the product into multiple parts. For example, we designed a four port monopulse comparator in a single printed component which weighed 12 ounces. A representative part made from machining/braising/casting would weigh 2 to 7 pounds and require 10 to 20 waveguide pieces. This link is an example of a brazed monopulse comparator:
http://www.sylatech.com/microwave-products/monopulse-comparators
The surface finish of 3D metal printed metal has higher roughness than a polished metal surface. This leads to slightly more loss per length on a 1:1 basis. However RF performance is a often represented in a measurement such as insertion loss, which is affected not only by surface roughness but also overall length, connector mismatch, and any imperfections in the manufacturing process, such as slag in braising or misalignment in bolted together machined components. Our design and manufacturing processes significantly reduces not only total length but the number of connectors and imperfections found in other manufacturing processes. When we design a system, we combine multiple RF components into a single part, thereby reducing the total system loss. The result is less insertion loss when compared to standard manufacturing practices.
Our additive manufacturing process can maintain the tight tolerances necessary for operation of low-loss RF components up to 110 GHz, with high part-to-part precision. This allows for high consistency from one printed part to the next. We will design, test, and verify the RF performance of the 3D printed parts we fabricate so that you know every system will work.
Optisys has an anechoic chamber for performing sophisticated RF testing, analysis and certification of our designs. Our standard for product delivery is first article (1 unit) RF bench testing, pattern and polarization testing, and VSWR testing for subsequent units - all done on site in most cases. Additional RF testing options are available, and an RF test protocol and testing can be provided based on customer requirements.
Optisys uses industry recognized mechanical shock load testing standards determined by the use environment. For space applications, standard launch vehicle Shock Response Spectrum (SRS), with attenuation applied per NASA GEVS guidance is our design standard. For aerospace applications, In the absence of program-specific requirements, Optisys designs hardware in accordance with common aerospace practices, including MIL-STD-810 environmental standards, MIL-STD-461 EMI/EMC guidelines, and an AS9100-compliant quality management system. This is done through best design practices, with the ability to show compliance through analysis or testing if directed by the customer. Optisys can also develop a testing protocol specific to our customer’s directed requirements, with the ability to show compliance through analysis or testing as directed by the customer.
For space applications, Random vibration loads are defined in accordance with NASA GEVS (Table 5). If testing is required, the duration shall follow GEVS guidelines: two minutes per axis for qualification testing and one minute per axis for acceptance testing. This is done through best design practices, with the ability to show compliance through analysis or testing if directed by the customer. Optisys can also help develop alternative protocols for space, aerospace, and terrestrial applications with the ability to design to, and then test to those test protocols.