Efficient, Low-Loss Combiner Technology for Affordable Transmit and Receive Module Manufacturing

Nuvotronics has developed an improved manufacturing method for RF power combiners with improved efficiency performance, cost-competitive with existing COTS technologies from S-band through millimeter-wave frequencies. Our couplers offer significantly higher power performance compared to existing COTS parts as well. The technology has broad applications in Navy radar, electronic warfare and communications systems that require solid-state power-combined amplifiers with power levels to hundreds of watts. We streamlined our exclusive PolyStrata® microfabrication process to batch-manufacture affordable 3D couplers using plated copper on low cost large-format substrates. Couplers developed during this program are fully compatible with automated module assembly, require no critical wire-bond geometries, and are held to micron tolerances that improve repeatability. Next generation radar and EW systems will benefit from this technology by enabling more affordable and efficient solutions. Measured data from generic test articles fabricated in the Phase I study have been provided to defense primes, to underscore improved performance parameters. During Phase II we will accommodate specific design solutions for Navy programs, enabling rapid transition to programs of record.