W-Band Radar in LTCC

A defense research organization required compact, high-performance radar systems operating at millimeter-wave frequencies for short-range sensing applications. Conventional PCB-based approaches could not meet the integration density, thermal management, or RF performance requirements at W-band frequencies.

The core challenge was twofold: achieving the required RF performance at 77 GHz while maintaining a form factor suitable for embedded deployment, and solving the power amplifier integration problem that limited effective radar range in existing solutions.

Without a breakthrough in packaging technology, the radar systems would remain limited to laboratory demonstration rather than field-deployable capability. The research program required proven, characterized hardware to advance to the next phase.

The engagement covered the complete hardware development lifecycle: electromagnetic simulation of multilayer structures, physical design in LTCC, coordination with domestic fabrication facilities, and comprehensive RF characterization in an anechoic chamber environment.

The engagement delivered fully characterized W-band FMCW and K-band SFCW radar modules in LTCC packaging, ready for integration into the research program's next phase. Each module included integrated antenna arrays, feed networks, and the novel power amplifier assembly.

The patented power amplifier mounting method addressed thermal and RF grounding challenges that limited comparable designs, enabling measurable improvement in effective radar range without increasing module size or power consumption.