404 Not Found

Flann Microwave Ltd is a global market-leading designer and manufacturer of precision waveguide products, solutions and services to the Telecom, SATCOM and Aerospace markets. Trading since 1956, with a workforce consisting of highly skilled engineers and professionals, Flann continually stretches the limits of possibility with waveguide solutions not available else where on the market.

We have held a prominent presence in the SATCOM markets for decades, offering instruments such as antennas, antenna feed systems, waveguide switches and other componentry required by our customers. In 2015 Flann took a considered step toward establishing ourselves as a key part of the growing Space industry after being approached by the Jet Propulsion Laboratory (JPL NASA) to provide critical components not available elsewhere. From here, we have continued to provide bespoke solutions for Spaceflight missions occurring around the world.

NASA JPL SWOT satellite mission

As part of the NASA JPL Surface Water and Ocean Topography (SWOT) satellite mission, a requirement was identified for fixed attenuators with very stable performance over time, and across the range of environmental conditions, within the extreme Space environment. In response Flann designed and built a selection of Spaceflight Fixed Attenuators that would retain their calibrated performance, ready for installation into two phased matched Ka-band waveguide channels.

Methods developed to support Spaceflight qualification included: bolted rather than brazed construction, load element dual retention, mechanical encapsulation, secondary bonding, and viewing lids to allow full inspection of bond lines.

SWOT, launched on December 16th 2022 with our two attenuators installed, these enable consistent, high accuracy mapping of Earth’s surface water, from its harsh Space environment.

25480 Thin Wall Spaceflight Waveguide HDi

ESA Metop-SG 2nd Gen satellites

In 2018, Flann successfully won the tender to supply a range of V-band and W-band complex waveguide sections for mm-wave receivers on European Space Agency (ESA & EUMETSAT) Metop-SG 2nd Gen satellites. The series of six meteorological satellites are due to commence launches from 2025 to 2039.

This extremely challenging application required Flann to produce ultra thin wall waveguide components comprising of one-piece sections of copper waveguide with plated internal surfaces. During the manufacturing process, CT scans (x-ray) & cross-sectional analysis were used to confirm solder penetration in flange joints, and critical internal surface coating thickness.

These high precision devices underwent Spaceflight qualification testing managed between Flann, RAL Space and Airbus, and with delivery completed, these are now being integrated ready for launch.

Compact spaceflight switch

The huge demand from individuals and businesses for more high-speed data services, will continue to lead to an explosion in the number of satellites in LEO. Flann undertook a funded development project aimed at advancing the state of the art in waveguide technology for super high capacity satellite communication links.

Our precision electro-mechanical waveguide switch technology is ready to be tailored to mission-specific specifications with designs spanning 33 GHz to 220 GHz.

Flann have continued to develop more integrated solutions including combining the switch with diplexers, multiplexers, combiners, and couplers to make a complete light weight switching network for flight at ‘High g’ launch profiles.

Electro-Mechanical Switch

Stable across temperature extremes
Non-contacting detent mechanism
High Power, High Isolation & Low PIM

Flann’s Spaceflight switch is now available up to 220 GHz with work continuing to extend this further. An option for a ‘New Space’ approach has also been developed which is now available.

SATCOM DC-Operated

High isolation & Low insertion Loss
High reliability (>1,000,000 actuations)
Sealed, Pressurisable to 15 psi(g) standard

Flann’s highly successful range of test & measurement switches extends to SATCOM. Designed for both internal and external usage with applications including: SATCOM Systems, Switching Networks and SNG.

Filters

Greater than 80 dB stop band rejection
COTS high frequency models up to 500 GHz
Standard low pass filters for test & development

Flann can quickly develop custom filters with confidence going straight from simulation to final product, using a variety of topological features to arrive at the required performance.

Couplers & Attenuators

Retains Calibration in extreme Space Environment
Aluminium, split-block design with Load Element Dual Retention
Available from 2.60 GHz to 500 GHz

Fixed level attenuators and high performance couplers enable consistent, high accuracy measurements in the extreme Space environments. Qualified design provides low risk for new bespoke models.

Antennas

Linear & circular options available, dual polarization available with antenna feed
High power phased array antennas & standard gain horns also available
Additive manufacturing techniques now used for high frequency corrugated horns

Extensive range of antenna options available to suit any application. Inherently robust while providing superior sidelobe and cross-polar performance where applicable.

Diplexers, Polarizers & OMT's

Diplexers & Polarizers available for custom Rx and Tx frequencies
OMTs available as narrow band or full band devices
Innovative compact designs

Bespoke or COTS models available to suit existing E-band and Q/V-band designations. Compact, rugged design ensure suitability for the toughest environments while offering optimal RF performance.

Waveguide Terminations

High Power Load - with background - Circle

Water cooled, thermal sink plate radiation and convection cooled options available
Finite Element Analysis (FEA) carried out to confirm compliance
Non shedding and designed with stress equalisation

High and low power terminations available using various cooling methods to meet the toughest of demands, regardless of the application. Extensive legacy supplying into ground-based TVAC environments.

Complex Waveguide Solutions

25480 Thin Wall Spaceflight Waveguide HDi - circle

High RF performance using a thin wall, low mass, compact solutions
Optional materials, finishes and interfaces available
Models available from 2.6 GHz to 1.1 THz

Complex waveguide solutions enable seamless connection between custom positioned ports. Ability to incorporate multiple bends, twists and other features to meet bespoke requirements while withstanding extreme Space environments.

Waveguide-Coaxial Transitions

Rugged metal construction with air-line coax for extreme environments
Various waveguide and coaxial interfaces available
End launch or alternative profiles also available

Building upon decades of supply of waveguide to coaxial adapters, spaceflight options are now available as either bespoke or COTS and to suit narrowband or full waveguide band frequencies.

Satellite Calibration

Goonhilly Earth Station is one of very few calibrated facilities in the world for very high accuracy measurement of satellite performance. Flann retrofitted componentry including wideband diplexers to an existing collapsible dish antenna feed on location, in Cornwall UK.

Their capability to operate in both the Southern and Northern hemispheres (horizontal and vertical polarisation) is due to a complex waveguide switching matrix, delivered by Flann, that is calibrated as a single assembly and which enables a high accuracy rugged re-locatable Reference.

Long lifetime Waveguide Switch

United Kingdom’s National Weather Service (Met Office) had concerns about reliability and life span of waveguide switches in their rainfall radar network from a previous supplier. They rely on these for a 24/7 service but they are based in remote locations all over the UK.

The Met Office approached Flann to see how we could alleviate these concerns and what we had to offer. Flann carried out accelerated lifetime tests and provided a direct replacement switch.

Flann provided additional feedback on how to extend the lifetime even further. The Met Office have subsequently ordered Flann switches for each radar in their network.

High Power Klystron Testing

High power millimetre wave (mm-wave) instruments are attracting more interest as communications networks are progressing higher in frequency to accommodate the need for higher data transfer speeds. An application where this combination of high power at high frequency is required, is for satellite uplinks & downlinks.

This led to us designing & manufacturing a water cooled Dual Coupler & High Power Termination suitable for 300W CW for Communications & Power Industries Canada Inc (CPI). These instruments are integral to their high power test bench, which ensures compliance of their latest range of Extended Interaction Klystrons (EIK’s) at 61 GHz.