Waveguide Antennas in Perfection
High-performance injection moulding and metallisation for waveguide antennas with the highest quality standards
Why polymer waveguides?
Waveguide antennas require complex 3D waveguide structures and maximum precision in metallisation. In addition, they must withstand thermal and climatic stress and, depending on the application, also a soldering process. For this purpose, we rely on high-performance polymer.
Together, we develop solutions that improve your product in terms of:
- Cost efficiency: series production by injection moulding
- Design freedom: complex geometries can be realised
- Service life: choice of layers in metallisation, adhesive strength, corrosion resistance
- Function: optimised conductivity and efficiency
Our technological focus areas
Benefit from our many years of experience – particularly in these areas:
Materials for the most demanding requirements
We have many years of experience in selecting the optimal high-performance materials (PPS, PEI, COC, LCP, IXEF, etc.) for your specific application and would be happy to advise you in this regard
- Temperature resistance up to >260 °C
- Metallisation capability
- Precision injection moulding
- HF-optimised selection for minimal losses
Precision in injection moulding
Our tools and processes are designed to ensure that every detail is correct in the micrometre range – from the prototype to series production.
- Multi-cavity tools for series production
- Tool life thanks to wear protection coating
- Micro-precision & burr-free breakthroughs
- Quality control using image processing, up to 100% inspection if necessary
- Automation
Coating technologies
We use innovative coating systems to make polymer conductive, resistant and suitable for high frequencies
- Electroplating & chemical metallisation, also on PPS
- Sputtering, especially for thinner coatings with high surface quality
Quality assurance
Every component undergoes comprehensive testing – so that in the end, exactly the performance your project needs is achieved
- SPC-monitored injection moulding process, shot-to-shot documentation on request
- Control and monitoring of burr formation
- DoE for systematic derivation of control variables for the process
- Layer thickness measurement & functional test
Radar antenna with copper coating (possibly also with additional coating layers)
Radar antenna with silver coating as functional top layer
Your advantages with VIAOPTIC
With VIAOPTIC, you are choosing a partner that combines experience, technology and innovative spirit – and accompanies you from the initial idea to series production
- Innovation leadership in polymer optics & coatings
- Made in Germany – quality & reliability
- From prototype to series production – everything from a single source
- Strong partner networks
Trust based on expertise
Our customers rely on certified quality – and we deliver. As an IATF 16949-certified company, we meet the globally recognised quality standards of the automotive industry. This means:
- Seamless process reliability
- Documented traceability
- An uncompromising focus on zero-defect strategies
FAQ - Do you have any questions?
We have the answers – clear, understandable and to the point
Which polymer are suitable for metallisation?
Unlike decorative metal coatings, for which there have long been well-functioning plastic + coating systems (mostly ABS or PC/ABS-based), radar systems require plastics that must meet completely different requirements. Depending on the requirements, we rely on high-performance polymers such as PPS, COC or LCP. PPS impresses with its high heat resistance (>260 °C) and good HF properties and is well known for metallisation in headlight reflectors, while COC and LCP offer particularly low loss factors and LCP is known for metallisation in the 3D-Mid process. We can advise you on your specific requirements. We select the material base and metallisation for each application and product requirement.
Which coating processes are used?
Electroplating (Cu, Ni, Ag, Au) – for high conductivity and, in particular, for uniform layer thicknesses, even in areas that are difficult to access.
PVD sputtering – for thin, high-precision functional layers in a process with very low process variations and low costs for high quantities.
How should the operating limits (temperature, climate change, etc.) of suitable polymer + coating system substrates be assessed?
Temperature resistance:
With the right choice of plastic, temperature change resistance between -40 and +150°C is also possible in continuous change resistance tests.
Short-term injection loads in the range >260°C can also be achieved.
The exact operating limits always depend on the selected polymer, the coating system and the coating process and should therefore be optimised and tested on a project-specific basis.
- PPS (e.g. Torelina A675 GS1): >260 °C (HDT), low thermal expansion coefficients
- COP/COC: very good HF properties, but more limited temperature resistance
- LCP: advantageous for HF losses, thermally stable, good electroplating properties
- IXEF; high thermal load capacity, low expansion coefficients, good electroplating properties
What is the service life of the serial tools?
The service life of our series tools is a decisive factor for quality and cost-effectiveness. When processing high-performance plastics such as PPS, we rely on wear-protected tool surfaces, for example through CrN or DLC coatings. This ensures that service lives of one million cycles and more can be achieved, even under demanding conditions. Precise hot runner control is essential, especially for multi-cavity tools with 8 to 16 cavities, in order to ensure consistent quality without burr formation. Careful tool maintenance and the right combination of material, design and coating contribute significantly to a long service life and consistently high component quality.
What technical cleanliness criteria are required and how are they achieved?
Technical cleanliness is a basic requirement for reliable coating and thus for the functionality of the components. Even the smallest particles, burrs or residues can impair the adhesion of metal layers and reduce electrical and mechanical performance. That is why we attach particular importance to burr-free components, dust-free surfaces and residue-free pre-treatment. To achieve these standards, we rely on modern processes in toolmaking, precise hot runner technology, process control of multiple cavities and thus burr minimisation, and wet chemical or plasma-assisted cleaning processes for the tool inserts. Particularly sensitive components are also handled in a clean room environment. In this way, we create the necessary basis for durable, high-precision and functionally safe coating systems.
You know what you need – we know how to make it
Contact our sales team!
Philipp Hornik – Head of Sales
Marcel Pfeifer
Dr Markus Cremer
Telephone: +49 6441 9011-458
Email: sales@viaoptic.de
