The paper presents a new concept in antenna design, whereby a photo-imageable thick-film process is used to integrate a waveguide antenna within a multilayer structure. This has yielded a very compact, high performance antenna working at high millimeter-wave (mm-wave) frequencies, with a high degree of repeatability and reliability in antenna construction. Theoretical and experimental results for 70 GHz mm-wave integrated antennas, fabricated using the new technique are presented. The antennas were formed from miniature slotted waveguide arrays using up to 18 layers of photo-imageable material. To enhance the electrical performance a novel folded waveguide array was also investigated. The fabrication process is analysed in detail and the critical issues involved in the fabrication cycle are discussed. The losses in the substrate integrated waveguide have been calculated. The performance of the new integrated antenna is compared to conventional metallic, air-filled waveguide antennas, and also to conventional microstrip antenna arrays operating at the same frequencies.
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