Alex A Marco

51828499, Feb 2, 1993

Dec 21, 1990

7/631826

Alex A. Marco - Torrance CA

Hughes Aircraft Company - Los Angeles CA

H01P 1100

29600

Disclosed is a method of producing a complex, lightweight, and low cost microwave waveguide components. First, a salt mandril (25) is formed into a desired shape by a compaction process. Next, an aluminum layer (50) is applied to the outer surface of the salt mandril (25) by means of a vapor deposition process. The thickness of the aluminum layer (50) can be made very thin. Plastic stiffeners (54, 56) can be added to outer walls of the aluminum layer (50) to increase the support of the waveguide walls and still maintain minimum weight. Next, the entire structure is submerged in an aqueous solution to dissolve the salt mandril (25). Machining of unwanted parts of the aluminium layer (50) can then be performed, and the inner surface of the aluminum layer (50) and exposed outer surfaces can be anodized (80). Gold plating (72) can be applied to appropriate surfaces of the aluminum layer (50) for an improved interface to attach the microwave component to other components to form a desired system. By this, complex and lightweight components can be fabricated.