Flexible Waveguide

Product Introduction

As a core flexible transmission component in RF microwave systems, Flexible Waveguide primarily resolves the issue of efficient electromagnetic energy transfer between misaligned waveguide ports or between static and moving system modules.  It consists of a flexible waveguide tube, inner dielectric support , and standard flange interfaces at both ends.  According to the structural material, common Flexible Waveguides include corrugated metal type, metal mesh type, and composite material type;  according to the operating frequency, they cover low-frequency to high-frequency ranges.

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Product Specifications

Product Benefits​​​​​​​

• Excellent flexibility: Corrugated or mesh structure design enables multi-directional bending, torsion, and axial adjustment, adapting to installation deviations and structural vibrations without performance degradation.
• Low insertion loss: Adopts high-purity metal for the waveguide tube and optimized dielectric support, ensuring minimal signal energy loss during transmission.
• Stable impedance matching: Precision-machined flange interfaces and uniform waveguide inner diameter achieve low VSWR across the entire frequency band, avoiding signal reflection.
• High power adaptability: Corrugated metal type uses thickened metal walls and heat-resistant materials, supporting long-term stable operation under high-power conditions.
• Strong environmental resistance: Sealed type adopts IP65/IP67 protection, resisting water vapor, dust, and salt spray corrosion;  high/low temperature models adapt to extreme environments.
• Easy installation: Flexible design eliminates strict alignment requirements during installation;  standard flanges enable direct connection with rigid waveguide systems.

Technical Features

• Corrugated structure optimization: Corrugated metal waveguide tubes adopt precise roll-forming technology, with uniform corrugation pitch and depth to balance flexibility and transmission performance.
• Low-loss dielectric support: Uses PTFE or ceramic dielectric spacers with low dielectric loss, arranged at equal intervals to maintain waveguide shape without increasing insertion loss.
• High-precision flange processing: Flanges are machined by CNC lathes, ensuring consistent interface dimensions and tight connection with rigid waveguides to avoid signal leakage.
• Sealing and shielding technology: Outdoor models use fluororubber gaskets and laser welding sealing, achieving IP67 protection.
• Material surface treatment: Waveguide inner surface is plated with silver or gold to reduce skin effect loss; outer surface is coated with anti-corrosion paint for outdoor durability.
• Reliability testing: All Flexible Waveguide products undergo bending fatigue tests, vibration tests, and high-low temperature cycling tests to ensure stable performance in complex environments.

Product Applications

• Communication systems: In microwave relay stations and satellite ground stations, Flexible Waveguide connects antennas and indoor RF equipment, adapting to antenna adjustment and structural settlement.
• Radar systems: In military fire-control radar and civilian weather radar, it connects rotating antenna pedestals and fixed transceiver modules, ensuring continuous signal transmission during antenna rotation.
• Aerospace systems: In aircraft radar, satellite communication payloads, and missile guidance systems, it adapts to vibration, shock, and temperature changes during flight, maintaining stable transmission.
• Test & measurement equipment: In RF microwave test platforms, Flexible Waveguide connects signal sources, analyzers, and test fixtures, facilitating equipment layout and reducing alignment difficulty.
• Industrial microwave equipment: In microwave heating, drying, and plasma processing systems, it connects microwave generators and load cavities, adapting to equipment vibration and thermal expansion.
• 5G/6G base stations: In active antenna systems (AAS), it connects radio frequency units (RRU) and antenna arrays, adapting to the compact layout and structural adjustments of base station cabinets.

OEM

Advanced Microwave provides professional OEM services for Flexible Waveguide to meet the personalized needs of different customer projects:

• Customized performance parameters: According to customer system requirements, customize Flexible Waveguide with specific frequency bands, power levels, insertion loss, and flexibility indexes.
• Structural and interface customization: Design non-standard flange interfaces, special lengths, and shaped flexible structures (e.g., right-angle pre-bent) to adapt to limited installation spaces.
• High-power/high-frequency customization: For high-power scenarios, develop thickened corrugated metal structures; for high-frequency (Ka/C-band) scenarios, adopt precision-machined waveguide tubes and low-loss materials.
• Branding and packaging customization: Support customer logo printing on flanges, custom color coating for outer surfaces, and provide shock-proof packaging solutions for long-distance transportation.
• Technical collaboration: Provide pre-sales technical consultation and post-sales installation guidance to assist customers in system integration.

FAQ

Q: What is the difference between corrugated metal and metal mesh Flexible Waveguide in application?

A: Corrugated metal Flexible Waveguide has higher power handling capacity and lower insertion loss, suitable for high-power scenarios such as radar and industrial microwave equipment. Metal mesh Flexible Waveguide is lighter and more flexible, with lower cost, suitable for low-to-medium power scenarios such as communication base stations and test equipment, but has lower power resistance.

Q: Can Flexible Waveguide be used in outdoor environments for a long time?

A: Yes. We provide sealed-type Flexible Waveguide with IP67 protection grade, which uses fluororubber sealing gaskets and anti-corrosion coated outer surfaces to resist water, dust, and salt spray. However, it is recommended to avoid direct exposure to sunlight for a long time; adding a protective cover can further extend its service life.

Q: Will repeated bending affect the performance of Flexible Waveguide?

A: Our Flexible Waveguide undergoes strict bending fatigue tests. Under normal operating conditions, repeated bending will not significantly reduce insertion loss or isolation. However, excessive bending or frequent bending at the same position may cause metal fatigue or dielectric support damage, so it is recommended to follow the bending specifications in the product manual.

Contact Us

If you need a high-performance Flexible Waveguide to solve signal transmission problems in misaligned or dynamically moving RF microwave systems, contact us now to get customized solutions tailored to your project!

📧 Email: [sales@admicrowave.com]