what's rigid 6061-T6 waveguide WR28(straights, bends, twists, transitions) Ka band for starlink? where's satellite waveguide(antennas, tubes ) 6063 aluminium manufacturer? how to custom millimeterwave waveguides, components, and flanges for space?

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manufacturer of satellite millimeterwave components (straights, bends, twists, transitions)E band ! supplier of custom starlink waveguide (filters, couplers, attenuators, intracavities, feed horns,) and flanges!

we manufacture the Metal structures for starlink’s WR28 sWaveguide chains

We are a specialized contract manufacturer focusing on millimeter‑wave and sub‑millimeter‑wave metal components. We do not design complete RF devices, nor do we assemble entire systems. Instead, we machine waveguide cavities and structural parts exactly to customer drawings – and our customers include suppliers working on Starlink’s Ka‑band (WR28) links.

What do we make? The critical metal bodies of: Straight, bent, twisted, and transition waveguides. Iris filters, diplexers, and multiplexer cavities ,Circulator and isolator housings, Choke flanges, coupler bodies, and feed horn cavities. All these parts are made from 6061 aluminum (or other specified alloys), with inner surfaces plated in silver or gold. They are the “plumbing” that connects active RF chips to antennas – but we only supply the precision‑machined shells, never the ferrites, magnets, or semiconductor dies inside.

Why us? Because WR28 Ka‑band requires extreme accuracy: Dimensional tolerances: ±5–10 µm Surface finish: Ra < 0.2 µm (mirror‑like) Complex 3D features: E/H‑plane bends, 90° twists, thin iris windows, and λ/4 choke grooves.

typical WR28 waveguide chain – starlink satellite (Ka-band)

Comp	Qty	L (mm)	IL (dB)	Material
WR28→2.92mm Trans	1 pc	25 mm	0.20	dB 6061Al+Au
Straight WG	2 pcs	30 mm, 20 mm	0.02 dB ea	6061Al+Ag
Isolator	1 pc	15 mm	0.30 dB	Ferrite
Straight WG	1 pc	25 mm	0.02 dB	6061Al+Ag
Circulator	1 pc	15 mm	0.30 dB	Ferrite
E‑plane 90° Bend	2 pcs	–	0.10 dB ea	6061Al+Ag
Straight WG	2 pcs	40 mm, 40 mm	0.03 dB ea	6061Al+Ag
Iris Filter	1 pc	50 mm	0.50 dB	6061Al+Ag
Straight WG	1 pc	25 mm	0.02 dB	6061Al+Ag
90° Twist	1 pc	60 mm	0.10 dB	6061Al+Ag
Diplexer (Tx/Rx)	1 pc	80 mm	0.50 dB	6061Al+Ag
Straight WG	1 pc	50 mm	0.05 dB	6061Al+Ag
Choke Flange	1 pc	10 mm	0.05 dB	6061Al+Ag
Feed Horn	1 pc	70 mm	0.10 dB	6061Al+Ag

starlink straight waveguides (WR28),most basic and most commonly used.

parameter	value	unit	condition
Waveguide Size	WR28 (WG22 / R320)	—	MIL-DTL-85H
Frequency Range	26.5 – 40.0	GHz	Full band
Cutoff Frequency (TE10)	21.08	GHz	Theoretical
Inner Width (a)	7.112 ±0.005	mm	Broad wall
Inner Height (b)	3.556 ±0.005	mm	Narrow wall
Wall Thickness	1.0 – 1.5	mm	Standard
Material	6061-T6 Aluminum	—	Aerospace grade
Inner Coating	Silver (Ag)	—	Electroless + electroplated
Coating Thickness	5 – 10	um	On inner surface
Surface Roughness (inner)	Ra ≤ 0.2	um	After plating
Length (standard)	25, 50, 100, 150, 200	mm	Custom lengths available
Length Tolerance	±0.05	mm	For critical phase-matched pairs
Flange Type	UG-599/U (cover flange)	—	MIL-F-3922
Flange Hole Pattern	4 holes, Ø3.6 mm on 21.1 mm circle	—	Square pattern
Insertion Loss	≤0.05	dB/100mm	@ 30 GHz, silver plated
VSWR	≤1.05:1	—	straight section with flanges
Power Handling (CW)	1.5 – 2.0	kW	@ sea level, matched load
Power Handling (space)	0.5 – 1.0	kW	@ vacuum, no convection
Phase Length Tolerance	±1.0	degree/100mm	@ 30 GHz for matched pairs
Mass	8 – 12	g/100mm	Aluminum, with flanges
Leakage (RF)	≤ -100	dBc	With choke flange or gasket

waveguide bends used in satellite (Ka-band, WR28) millimeterwave parts

parameter	value	application in Starlink (WR28, 26.5–40 GHz)
Waveguide type	WR28 (rectangular)	Satellite feeder link (Gateway ↔ Satellite)
Frequency range	27.5 – 30.0 GHz (Tx) / 17.7 – 20.2 GHz (Rx)	Tx/Rx separate paths
Bend types used	E‑plane bend, H‑plane bend, Miter bend (90°), Smooth bend	Routing around thrusters, batteries, star trackers
Typical bend angle	90° (most common), 45°, 60°, 180°	90° used in 80% of satellite internal layouts
Bend radius (E‑/H‑plane smooth)	15 mm – 25 mm (≥ 2× waveguide width)	Compromise between low loss and compactness
Insertion loss per 90° bend	0.05 – 0.10 dB (smooth bend)	Budget: <0.5 dB for all bends per satellite
Return loss (VSWR)	< 23 dB (VSWR <1.15)	Maintained across full Ka-band
Number of bends	per satellite 4 – 8 pieces	Average ~6 bends per Ka‑band payload
Total loss contribution	0.3 – 0.5 dB (all bends combined)	Within link margin (typical fade margin 3–5 dB)
Surface finish	Inner wall: Silver plating (5–10 µm)	Improves conductivity (skin depth ~1.3 µm at 30 GHz)
Manufacturing tolerance	±10 um on inner dimensions	5‑axis CNC milling
Power handling (CW)	50 – 100 W	(with silver plating) Well above typical satellite Tx power (5–20 W)

We achieve this with 5‑axis CNC machining centers, complemented by EDM and precision lapping where needed. Every cavity is cut from solid 6061Al, then plated. No casting, no 3D printing – only subtractive manufacturing that meets space‑grade reliability.

To be clear: we do not design the filter, the diplexer, or the horn. We simply read your drawing, choose the right toolpath, and deliver a metal cavity that fits your electrical design perfectly. If you need millimeter‑wave waveguide structures made exactly to your specs – without design work, without unwanted extras – we are your shop. Send us your WR28 (or even higher) drawings, and we will machine them.