Adaptive Thermoforming and Structural Design of Millimeter-Wave Antenna Panels

Future large-scale radio telescope observatories, such as the next-generation Very Large Array, involve extremely large collection areas. These collection areas are divided into smaller shaped panels, which typically require their own unique molds to manufacture. For these projects to be cost-effective, an efficient fabrication method for the shaped panels is needed. This paper outlines the development and success of a novel adaptive freeform panel molding technology that greatly improves manufacturing efficiency due to its repeatable and reusable nature. Moreover, it presents an analysis of a proposed panel structural design for the shaped panels, which incorporates a study on surface deformation due to gravity and wind loading under realistic operational conditions.