Saxonia and Freudenberg Are Developing Metallized Waveguide Antennas

Saxonia Galvanik is a development partner of Freudenberg Sealing Technologies for new applications in automotive radar sensor technology. Freudenberg, working with a specialized program team, develops and manufactures waveguide antennas for radar sensors used by leading Tier 1 companies in the automotive supply industry. The plastic components used for this purpose, which feature fine waveguide structures, are produced using injection molding. To achieve the electrical conductivity required for the radar application, the components are subsequently metallized at Saxonia Galvanik. The company contributes its expertise in the functional metallization of plastics and metals to the development partnership. For the production of the new components, a large-scale electroplating facility was retrofitted specifically to meet the requirements of waveguide antennas. Saxonia and Freudenberg conducted extensive test series and have already produced prototypes and sample quantities in production-quality. In addition, various coating systems were tested, which, according to the companies, are now nearing production readiness.

Electrolytic Plastic Metallization for Radar Sensors

In addition to the function of the metallized surfaces, a key focus of the development is on an economically viable overall process for high-volume production. Material selection, coating systems, component design, and the electroplating production process are tailored to the respective waveguide geometries and requirements of the radar sensors. Waveguide antennas are three-dimensional waveguide antennas in which high-precision plastic structures become electrically conductive through a metallic coating. The technology is intended, in particular, to improve the RF characteristics and performance of modern radar systems while simultaneously allowing for a high degree of design freedom in antenna design. Depending on the application, single- or multi-layer structures can be implemented, and the layer systems can be adapted to the requirements of sensor integration. This makes the metallized plastic waveguides suitable, among other things, for radar sensors in advanced driver-assistance systems (ADAS) as well as for applications in automated and autonomous driving. Simulations and prototyping support the development process through to planned series production.