Horn Arrays
Optisys horn arrays are a production-proven, high-TRL antenna solution designed for scalability across both frequency and gain. Horn arrays are one of our most proliferated technologies, with multiple designs currently on orbit supporting a range of missions, orbits, and operational environments. By leveraging additive manufacturing, Optisys produces highly efficient horn and waveguide geometries in extremely compact volumes—achieving significant mass and volume savings compared to traditionally machined or assembled horn arrays. This enables higher performance in smaller envelopes without the penalties of complex assembly or alignment.
Additive manufacturing allows Optisys to integrate multiple RF and mechanical components directly into a single horn array structure, waveguide transitions, mounting features, and interfaces that would traditionally require multiple parts and fasteners. The result is a monolithic, repeatable antenna architecture that delivers consistent performance across builds and over time. Automated horn arrays are especially well suited for constellation programs, where repeatability, supply-chain stability, and the ability to support multiple follow-on orders are critical. To further reduce program risk and cost, Optisys offers several standard horn array configurations that eliminate or significantly reduce non-recurring engineering (NRE).
Typical horn array performance characteristics include:
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Medium to high gain, scalable through array size and element count
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Frequency scalability across bands using a common design architecture
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Excellent SWaP efficiency driven by compact, integrated waveguide geometries
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High unit-to-unit repeatability across multiple builds and orders
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Significant mass reduction versus traditional machined horn arrays
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Proven suitability for constellation and at-quantity production
Key Takeaways
Optisys automated horn arrays combine high-TRL, on-orbit heritage with additive manufacturing to deliver lightweight, repeatable, and scalable antennas—available in standard configurations that minimize risk and eliminate unnecessary NRE.
Why Additive Manufacturing Matters Here
Horn arrays benefit dramatically from additive manufacturing, where complex waveguide paths, tightly packed horn geometries, and integrated transitions can be realized without assembly or alignment penalties. This enables Optisys to pack high-performance RF structures into small volumes while reducing mass and part count. The result is a robust, flight-ready antenna that scales efficiently from prototype to constellation production.
Optisys designs are covered by one or more patents.
