Ka-Band 16-Channel T/R Module Based on MMIC with Low Cost and High Integration

Based on monolithic microwave integrated circuit (MMIC) technology, this paper presents the design and implementation of a low-cost, highly integrated Ka-band sixteen-channel transmit/receive (T/R) module, specifically tailored to meet the application requirements of phased array antennas in airborne and spaceborne radar systems, satellite communications, and 5G/6G millimeter-wave networks. The proposed module employs an MMIC-based single-channel dual-chip discrete architecture, optimally integrating amplitude-phase multifunction chips and transmit-receive multifunction chips in terms of both fabrication process and performance characteristics, achieving a favorable balance between high performance and high-integration density. Using low-cost, low-temperature co-fired ceramic (LTCC) substrates, full-silver conductive paste, and a nickel–palladium–gold plating process, a novel “back-to-back” thin-slice packaging technique is presented to improve integration, lower manufacturing costs, and boost long-term reliability. Furthermore, the design incorporates glass insulators and a direct array interconnection scheme, which significantly minimizes transmission losses and reduces interface dimensions. The final module measures 70.3 mm × 26.2 mm × 10.9 mm and weighs only 34 g. Experimental results demonstrate a transmit output power of at least 23 dBm, a receive gain exceeding 26 dB, and a noise figure below 3.5 dB, achieving a 22.5–58% reduction in volume per channel while maintaining competitive RF performance. To improve testing effectiveness and guarantee data consistency, an automated radio frequency (RF) test system based on Python 3.11.5 was also developed. This work provides a practical technical approach for the engineering realization of Ka-band phased array systems.