“Hello Giggy,” is a one-meter offset dish that needed a circularly polarized feed for 2304 MHz Earth Moon Earth digital communications experiments. This is the story of how that feed went from a parameterized OpenSCAD file to working aluminum feed horns. The journey began with paper dolls, bend allowance coupons, SendCutSend’s design rule checker, and three different electromagnetic simulation programs. We learned a lot from when things went wrong. The process from paper to working feed took four weeks.
Choosing the Design
Circularly polarized septum feeds are what are generally used on EME dishes. They are built from a square waveguide that is divided by a metal plate. The metal plate is cut on the diagonal in a stair-step style. These steps convert each of two rectangular ports into left- or right-hand circular polarization. One is used for receive and the other is for transmit. The first set of design work for this feed had derived all the dimensions from the classic Chen & Tsandoulas paper. It turns out that this describes a design that requires a dielectric to work properly. All-metal amateur septum feeds tend to use OK1DFC’s published 23 cm design, verified in HFSS by Paul Wade W1GHZ and built into a wide variety of EME stations.
So we started over. The final dimension set is the OK1DFC 1296 MHz spreadsheet values scaled by exactly 1296/2304 = 0.5625: an 81.51 mm square guide, a five-step septum, and a 1.4-wavelength flared aperture chosen from W1GHZ’s published tables for our dish’s f/D of 0.83. Every number in the design traces to one source through one scale factor and stays true to known-good EME feed designs.
One File to Rule Them All
The entire feed lives in a single parametric OpenSCAD file. It contains the verified 1296 reference values, the scale factor, a bend-allowance model, every flat pattern, a 3D verification visualization, and an echo block that prints a human-readable build sheet, bend line positions, check dimensions, and hole positions. If you change the frequency, the material thickness, or the bend parameters, then everything scales as it should.
There are two Python scripts. One generates a set of dimensioned drawings and the other generates vendor-ready flat-pattern cut files, based on SendCutSend’s file requirements. SendCutSend is the company we ended up going with to cut and bend the metal parts for the feed.
Paper Dolls
Before cutting any metal, we printed the flat patterns at full scale on cardstock and built the feed with tape and glue. This sounds quaint, but the process found real bugs, as expected. The septum was missing corner notches that the backshort cap needs to slip over the assembled tube. It found every place where holes seemed to be missing. This was forgotten and deliberate drill-after-fit decisions that hadn’t been correctly documented. A fellow SBMS builder’s paper doll was assembled with the connector at the wrong end, and this sparked a discussion about why the probe seems too close to the backshort. The probe sits only 24 mm from the backshort instead of the quarter-guide-wavelength rule of thumb. This is because the fat probe and the close backshort and the target frequency are a matched set.
The paper doll also revealed the right order to assemble the parts and what tools to make sure we had on hand in order to reach the fasteners. Both machine screws and rivets were used to assemble the feed, and the paper doll process let us sort it out before any metal was cut.
Bend Allowance, Coupons, and a Big Surprise
Sheet metal shrinks into its corners. A hat channel, which is the type of bend we were using for the waveguide body clamshells, is shorter than the sum of its formed dimensions by one “bend deduction” per bend. That deduction depends on the material, the tool used, and the operator. We designed a calibration coupon. This is an 80 by 30 mm strip, scribed at exactly 20 and 60 mm, and bent into a U-channel. Measuring before and after gives us the bend diameter of the shop brake we were using. This number goes into the OpenSCAD, so that the flat pieces will end up the right dimension when bent.
Paul bent five coupons. Some were with the grain and some were across the grain. Both sides were measured so that any skew could be averaged out. Results were that the grain effect was about 0.1 mm (3003 aluminum), and repeatability was about +/- 0.25 mm per bend. Stacked across the clamshell’s four bends, hand-brake repeatability alone could make about a millimeter of difference. And then we got a big surprise. Neither of the two shop brakes at Remote Labs could physically form the deep hat channel anyway! This part belonged on a press brake.
SendCutSend and the Design Checker
We sent out dimensioned drawings and got a quick and polite reply. Their instant-quote pipeline wants cut geometry, not a bunch of documentation. Their published bending calculator gives the K-factor and bend radius their press brakes use for each material. For 0.040″ 5052-H32, K = 0.45, R = 0.6096 mm, bend deduction was 1.5755 mm, which our own formulas reproduced to a thoroughly ridiculous four decimal places. Those numbers went into the OpenSCAD file as parameters, and the flat patterns exported. That is the entire vendor work flow. We take their constants, use our geometry, and then export the right type of document to upload to their website.
Their checker then gave us a compressed education in bend-line file conventions, which had to do with how a box or pan is specified for their bending and cutting machines. In order, here’s what had to be corrected:
- A stray contour becomes a separate part. A leftover 0.3 mm sliver of scribe geometry in one file was interpreted as a second, below-minimum-size part and derailed the whole preview.
- Bend lines that meet at corners form a closed loop, which looks like an interior cutout. Our pan cap’s four bend lines joined into a square and the checker insisted that the face was a hole.
- Bend lines that cross are rejected as intersecting bends. Extending the lines past the part edges (a convention some CAM systems require) made things worse, and inflated the reported part size by a really large amount.
- The actual fix for perpendicular flanges is corner relief: a little circle at each bend-line intersection, radius at least bend radius plus material thickness plus 0.5 mm. With four R2.5 reliefs cut at the corners, the one-piece pan finally sailed through. The breakthrough came from refusing to believe a sheet-metal shop simply could not make a box, and going back to read their guidelines until we found why our pan/box/backshort refused to import into their workflow.
Parts arrived and were perfect. Our acceptance gauge was the septum itself. The full-height section was cut to exactly the 81.5 mm guide width at fit perfectly into the bolted clamshell pair.
Probes
The probes are 1/8″ brass rod. This design is W1GHZ’s “fat probe” that substitutes bandwidth for tuning screws. Each rod was machined and center-drilled 1.3 mm by Paul Williamson. The rods were soldered over to the precisely cut pin of a flange-mount SMA. The SMA had extended PTFE dielectric which was trimmed flush with the inside wall. The rod seats against the Teflon face. This makes the wall end of the probe coplanar with the side of the waveguide, and exactly as long as it needs to be for 2304 MHz.
Soldering brass rod to an SMA pin can be done with a capillary joint. This can be intimidating, but with flux in the socket and a hot enough soldering iron, solder can be fed into the seam as soon as it is hot enough. While some people have had success with this method, the four probes (for two feeds) did not cooperate fully with this plan. The probe had to be lifted up slightly and the SMA pin and probe socket heated, and solder flowed into this joint, then the probe dropped fully onto the pin. This worked for all four pins. All four probes were soldered this way, and continuity checked before anything left the bench.
Simulation
We modeled the feed in openEMS, the free open-source FDTD solver, rebuilding the geometry from the same parameter block as the CAD. Brian Yee W6BY independently reconstructed the design in SolidWorks and ran it through CST, a commercial finite-element solver, with real lossy metals. Matt Smith AF0FO is making progress with HFSS.
The two completed solvers agreed on everything they could both compute. Axial ratio converging to about 1.2 dB (W1GHZ’s own tolerance analysis predicts about 1.5 dB for this dimension set), port isolation 23–25 dB, a 13 dBi pattern with 40 degree beamwidth and −18 dB sidelobes. This is good for the aperture. This is what our 0.83 f/D dish wants to see. Radiation efficiency with real aluminum and copper was 100% to within thousandths of a dB. These were all really good results.
The one number both solvers produced that caused a bit of concern was match depth, reading about −11 to −12 dB. Another dive into the W1GHZ literature explained why. The published dimension set seems to describe a thin probe compensated by a tuning screw. The fat-probe, screw-free variant that everyone actually builds was W1GHZ’s recommendation, but not as many updates about this design.
The Rigol answers the open question
With both feeds assembled, we calibrated the Rigol spectrum analyzer’s VNA mode with a short, open, and load at the far end of the cable chain, and measured all four ports.
Return loss at 2304 MHz: 17 to 19 dB on every port of both feeds, SWR between 1.24 and 1.34, with the two independently built feeds matching each other to within 0.1 SWR. Port-to-port isolation, measured as vector S21: 22.5 dB on one feed, 23.7 dB on the other, against a simulated prediction of 22.8.
The trace itself answered a question Paul asked that deserves a permanent answer: shouldn’t we see a nice dip at the design frequency? No, and the flat trace is the design working. Narrowband antennas match through a single sharp resonance and show a V at their frequency. The fat probe is deliberately low-Q. It makes a broad shallow bowl, under 1.4 SWR across a 500 MHz window. The hardware came in 5 to 8 dB better than the simulations.
Then we carried the feeds around the neighborhood with a HackRF connected up to each one. We confirmed they worked with real radios attached and then we demonstrated the mirror rule of circular polarization, that two same-handed feeds facing each other are cross-polarized, on the air. The feeds work!
What’s Next
Next is connecting the feeds to a boom and sliding carriage to replace the dish’s Ku-band LNB arm. The feed’s phase center gets peaked on sun noise. Deep Space Exploration Society was interested a high-power variant of this same parametric design for their 18-meter dish. This would be the same OpenSCAD design with thicker walls, 7/16 DIN launch, and no flare for their deep prime-focus optics. Same file but with different parameters.
All the design files for the feed are in the ORI EVE repository at https://github.com/OpenResearchInstitute/EVE
Thanks to Paul KB5MU, Brian Yee W6BY for the CST validation, Matt Smith AF0FO and Chuck Hill for HFSS support, and the San Bernardino Microwave Society for additional paper dolls, technical support, and enthusiasm. Open Research Institute develops open source digital radio technology for experimentation and education.