Ka-band Hybrid for high throughput satellite

This paper discusses the design, in-house development and the challenges involved in the realization of Ka-band Hybrid for future Ka-band payloads. This is a single section 3-dB quadrature hybrid designed at 29.5 GHz to 30.0 GHz. This hybrid is developed for the first time at this band and is different from our convectional hybrid at C and Ku-band. The paper will address various critical aspects related to (1) electrical design-substrate selection, box resonance and its minimization, line width and its tolerances impact on RF Performance. (2) Mechanical design-package design, connector mounting mechanism. (3) Fabrication process- connector alignment in the package, 2.92 mm connector bead soldering by solder flow process.