Design, manufacturing, and DFMA analysis of a 5.3–7.27 GHz conical horn antenna

Abstract

This research provides a systematic validation and analysis of a conical horn antenna with a commercial frequency of 5.3-7.27 GHz. Theoretical validation of the main dimensions of the antenna such as the diameter of the waveguide, aperture size, flare angle, and overall length was compared with the design specification to guarantee that it meets the electromagnetic performance requirements. Material selection and surface finishing were assessed to maintain electrical conductivity, surface quality, and thermal stability, while manufacturing methods were evaluated to support dimensional accuracy and assembly feasibility. Electromagnetic behaviour simulation was done using High-Frequency Structure Simulator (HFSS) analysis to verify low VSWR, large gain, and radiation patterns. Design for Manufacture and Assembly (DFMA) principles were used in the development of a practical production concept, which would be manufacturable and structurally sound. The main contribution of this work is the integration of electromagnetic validation, material selection, manufacturing analysis, and DFMA principles into a single practical framework for developing a manufacturable conical horn antenna with high RF performance. These results indicate that the chosen antenna meets the RF performance and manufacturing criteria and offers a practical and reliable engineering solution that can be used in the real field.