Prototyping Process
This standardized process ensures efficient concept-to-product transition through a simulation-driven design, rapid iteration, and reliable mass production framework.
Stage 1:
Requirement Finalization & Design
1.1 Requirement Analysis Meeting
- IoT devices, 5G base stations, radar systems, medical equipment
- Single/multi-band (e.g., 2.4+5 GHz or 28 GHz mmWave)
- 3 dBi (omni) to 20 dBi (directional)
- Linear (V/H) or circular polarization (RHCP/LHCP)
- Max dimensions (e.g., 15×15×5 mm)
1.2 Simulation & Design
Tools: HFSS/CST/ADS for electromagnetic simulation
Design Steps:
- Initial structure design: Patch/IFA/slot antenna selection
- Parameter tuning: Feedline width, ground plane slots, parasitic elements
- Simulation validation: S11 curve (<-10 dB bandwidth),radiation efficiency (>60%), 3D radiation pattern
2.1 Material & Process Confirmation
Material Type / Applications
- FR4 / Low-cost, low-frequency (<3 GHz)
- Rogers 4350B / High-frequency/mmWave (5G/satellite)
- Flexible substrates (PI/PET) / Wearables/curved surfaces
2.2 Prototype Fabrication
PCB Antennas:
- Fabrication: 4-layer ENIG plating, impedance control ±10%
- Assembly: 0402 components hand-soldered, X-ray inspection
Structural Antennas:
- Metallization: LDS or electroless nickel/gold plating
2.3 Initial Testing
VNA testing: Keysight PNA with probe-tip calibration
- VSWR <2.0 in target band
- Return loss S11 <-10 dB
Stage 2:
Prototyping & Initial Testing
Stage 3:
Debugging & Optimization
3.1 Impedance Matching Tuning
Tools
- Smith Chart analysis
- Copper tape modification
Procedure
- Tune series/parallel LC for 50Ω match
- Test bandwidth extension with patches
3.2 Radiation Performance Validation
- Gain measurement: Reference horn antenna comparison
- Radiation pattern: H/V-plane polar plots (3 dB beamwidth ≥120°)
- Metal housing compensation: Decoupling structures/absorbers
3.3 Issue Resolution
Common Issues
- Frequency shift
- Insufficient bandwidth
- Low efficiency
Solutions
- Tune radiator length ±0.2λ
- Add parasitic elements/stub matching
- Verify dielectric loss (low-tanδ material)
Stage 4:
Final Validation & Delivery
4.1 Reliability Testing
Test Items
- Thermal cycling
- Vibration test
- Salt spray test
Standards
- -40℃~85℃, 5 cycles
- 20G@10-2000 Hz, 3 axes ×1 hr
- 5% NaCl, 96 hrs (outdoor models)
4.2 Deliverables
- Prototypes: 3-5 functional samples (with mounts/connectors)
- Schematics/PCB Gerber files
- Antenna Test Report (anechoic chamber data) Mass Production Guidelines (pad dimensions/tolerances)
Stage 5:
Mass Production Transition (Optional)
5.1 Pilot Production
- Process validation: FAI & CPK analysis (key dimensions ≥1.33)
- Test jigs: Automated RF test fixtures (≤30 sec/unit)
5.2 Special Antenna Considerations
Antenna Type
- mmWave antennas
- Flexible antennas
Key Requirements
- Laser drilling ±0.02 mm, Ra<0.5μm
- Bend test (10k cycles, R=3 mm)