Patent ID: 7948443

Claim:
A phased array antenna, comprising: a supporting material layer having an array of antenna element cavities, each antenna element cavity of the array of antenna element cavities having an aperture open to a front side of the supporting material layer and an interface open to a back side of the supporting material layer; a conductive layer lining each antenna element cavity of the array of antenna element cavities, the conductive layer lining formed by plating the conductive layer onto a mandrel matching each antenna element cavity, bonding the conductive layer into each antenna element cavity using the mandrel, and removing the mandrel leaving the conductive layer bonded into each antenna element cavity; a front side structural support facesheet affixed to the front side of the supporting material layer; and a back side structural support facesheet affixed to the back side of the supporting material layer; wherein the front side structural support facesheet comprises a non-conductive material.