Power leakage analysis of waveguide feeding structure.
RF Simulations at RFbeam Microwave
As an RF Engineer simulation is at the core of my work. At RFbeam we specialize in high-frequency electronics and radar systems, leveraging CST Studio Suite to drive our design process. Whether it’s antennas, PCB copper structures or radomes, simulations enable me to predict performance accurately long before the first prototype is built.
E-field simulation of an ultra-wide FOV antenna with radome effects.
One of the most rewarding aspects of my work is finding creative solutions tailored to our customers’ needs. From the initial concept phase to final measurements and verification, I’m involved every step of the way. Some applications demand antennas with high gain, wide bandwidth or a specific field of view, while others prioritize cost-efficiency for mass production. Balancing these requirements means carefully optimizing the trade-off between performance and cost.
Utilizing Dynamic Models in CST
Once the concept for a design – such as the type of antenna to use – is defined, I rely on CST’s powerful optimization tools to fine-tune a wide range of design parameters and achieve the best performance. However, RF performance is not my only focus; I also need to account for manufacturability, tolerance sensitivity and production scalability. In reality manufactured components often deviate from ideal simulations.
60GHz planar antenna with high sensitivity to etching tolerance.
CST enables me to model factors such as etching tolerances and substrate variations in PCB structures, as well as milling errors and mounting inaccuracies in antenna assemblies. Using these models, I can conduct tolerance studies in CST and predict the realistic performance of the final product. Additionally, I can implement specific measures to reduce the design’s susceptibility to real-world variations. These considerations are always central to my process, ensuring our designs are not only high-performing but also practical and robust for the customer’s application.
Innovative Waveguide Antennas for High-Performance Radar Systems
At RFbeam we’ve spent years refining a particular type of antenna and feeding technique to push the boundaries of radar performance. Traditional PCB-bound feeding mechanisms like microstrip suffer from significant losses at high frequencies such as 77 GHz and planar antennas often face limitations in gain and bandwidth. To overcome these challenges, we’ve developed waveguide feeding structures and antennas, which have become integral to our designs thanks to their exceptionally low loss, high bandwidth and high gain. Waveguide feeding structures offer roughly an order of magnitude lower loss per length compared to PCB-based counterparts – a critical improvement at these frequencies.
Section view of E-Field inside a 77GHz waveguide fed antenna.
Our development process spans a range of manufacturing technologies. We use CNC milling and Direct Metal Laser Sintering (DMLS) to create precise prototypes, while injection molding combined with metallization is planned for scalable production. In recent projects, I’ve focused on waveguide-fed slot antennas, which provide excellent performance in terms of gain and bandwidth. These designs are not only mechanically robust and compact, making them ideal for high-antenna-count radar systems (MIMO), but they are also meticulously optimized for efficient manufacturability. I’ve implemented several enhancements to ensure reliable performance, even when factoring in the tolerances of manufacturing and assembly.
77GHz 4-Layer waveguide MIMO antenna assembly
The integration of these waveguide-fed antennas into radar systems has led to substantial advancements in range, angular resolution and overall robustness. The reduced losses in the waveguide feed network and the superior gain of our antennas ensure that these designs meet the demanding requirements of modern radar applications, including automotive systems and beyond.
Verifications Using Measurements
While simulations are an essential part of the design process, accurate measurements are just as critical for verifying and refining our designs. At RFbeam we are equipped with sophisticated measurement capabilities that complement our simulations, allowing us to validate performance with precision.
77GHz 4-Layer waveguide MIMO antenna assembly tested with VNA.
We utilize a Vector Network Analyzer (VNA) capable of measuring scattering parameters up to 90 GHz. This allows me to analyze key RF metrics like insertion loss, return loss and impedance matching with high accuracy. For antennas, I can measure radiation patterns in our anechoic chamber, capturing critical parameters such as gain, beamwidth and sidelobe levels. These measurements ensure our designs meet the stringent requirements of real-world applications.
Beyond using off-the-shelf equipment, we often develop our own custom measurement setups to address specific challenges. For example, I’ve designed specialized equipment and methodologies to accurately measure PCB substrate properties or to characterize the dielectric performance of radome materials. These bespoke solutions allow us to extract valuable material properties enabling us to refine our simulations further and ensure that the final product performs as expected in its operating environment.
RFbeam proprietary broadband WR12 to microstrip transition with 20dB return loss at 67..90GHz.
About Me
Hi! I’m Dominik, an electrical engineer with a passion for high-frequency technology. I’ve been part of the RFbeam team since 2013, contributing to a wide variety of projects across the radar and RF spectrum. Over the years, I’ve tackled tasks ranging from radar signal processing software to system design and RF PCB design, giving me a broad and versatile skill set.
Currently my focus is on designing RF structures with a particular emphasis on antenna development. Leveraging both my programming skills and RF design expertise, I apply advanced modeling and optimization techniques to develop innovative solutions for RF components. This unique combination enables me to push the boundaries of what’s possible in RF design, creating efficient and high-performance solutions tailored to customer needs.
Conclusion
Thank you for joining me on this exploration of RF simulations and their role in our design process at RFbeam. I hope this blog has provided valuable insights into how we leverage simulation tools like CST Studio Suite, along with our advanced measurement capabilities, to create high-performance and reliable RF components. If you have any questions or would like to dive deeper into any of the topics discussed, feel free to reach out. Stay tuned for more updates and behind-the-scenes insights from RFbeam!
