ALIGNMENT AND CONSTRAINING DEVICES FOR MAINTAINING POSITIONAL OPTIMIZATIONS BETWEEN ANTENNA ARRAY COMPONENTS

1 . An antenna array comprising:

a radiating element configured to receive or transmit an electromagnetic signal; and

an alignment horn attached to the radiating element;

wherein the alignment horn comprises a detent end; and

wherein the radiating element and the alignment horn are manufactured together as a single element by a three-dimensional printing process such that manufacturing the single element does not require a separate joining process for joining separate components.

2 . The antenna array of claim 1 , wherein the detent end of the alignment horn comprises an ellipsoidal segment geometry.

3 . The antenna array of claim 1 , wherein the alignment horn further comprises a shaft;

wherein the detent end is attached to a distal end of the shaft; and

wherein a proximal end of the shaft is attached to the radiating element.

4 . The antenna array of claim 1 , wherein the alignment horn further comprises a shaft, and wherein the shaft comprises a conical frustrum geometry.

5 . The antenna array of claim 4 , wherein the conical frustrum geometry of the shaft comprises a proximal end and a distal end;

wherein the proximal end is attached to the radiating element and comprises a proximal diameter;

wherein the distal end is attached to the detent end and comprises a distal diameter; and

wherein the proximal diameter is longer than the distal diameter.

6 . The antenna array of claim 1 , wherein the antenna array comprises four radiating elements arranged in an orthogonal pair.

7 . The antenna array of claim 6 , wherein the four radiating elements arranged in the orthogonal pair comprises:

a first dipole comprising a first radiating element;

a second dipole comprising a second radiating element;

a third dipole comprising a third radiating element; and

a fourth dipole comprising a fourth radiating element.

8 . The antenna array of claim 6 , wherein arrangement of the four radiating elements arranged in the orthogonal pair comprises:

a first radiating element disposed adjacent to a second radiating element such that a first-second gap exists between the first radiating element and the second radiating element;

the second radiating element further disposed adjacent to a third radiating element such that a second-third gap exists between the second radiating element and the third radiating element;

the third radiating element further disposed adjacent to a fourth radiating element such that a third-fourth gap exists between the third radiating element and the fourth radiating element; and

the fourth radiating element further disposed adjacent to the first radiating element such that a fourth-first gap exists between the fourth radiating element and the first radiating element.

9 . The antenna array of claim 8 , further comprising a dielectric insert, wherein the dielectric insert is manufactured of a dielectric material; and

wherein the dielectric insert is configured to maintain spacing between the four radiating elements arranged in the orthogonal pair.

10 . The antenna array of claim 9 , wherein the dielectric insert comprises:

a first fin disposed between the first radiating element and the second radiating element to maintain the first-second gap;

a second fin disposed between the second radiating element and the third radiating element to maintain the second-third gap;

a third fin disposed between the third radiating element and the fourth radiating element to maintain the third-fourth gap; and

a fourth fin disposed between the fourth radiating element and the first radiating element to maintain the fourth-first gap.

11 . The antenna array of claim 10 , wherein the dielectric insert further comprises a stud, and wherein each of the first fin, the second fin, the third fin, and the fourth fin is attached to the stud.

12 . The antenna array of claim 11 , wherein the stud comprises a horn receptacle disposed therethrough, and wherein the horn receptacle is configured to receive the alignment horn.

13 . The antenna array of claim 11 , wherein the antenna array comprises an independent alignment horn attached to each of the four radiating elements arranged in the orthogonal pair such that the orthogonal pair comprises four alignment horns; and

wherein the stud comprises four horn receptacles disposed therethrough.

14 . The antenna array of claim 13 , wherein the four horn receptacles comprises:

a first horn receptacle configured to receive a first alignment horn attached to a first radiating element;

a second horn receptacle configured to receive a second alignment horn attached to a second radiating element;

a third horn receptacle configured to receive a third alignment horn attached to a third radiating element; and

a fourth horn receptacle configured to receive a fourth alignment horn attached to a fourth radiating element.

15 . The antenna array of claim 1 , further comprising a dielectric insert that comprises:

a stud comprising a stud thickness; and

a horn receptacle forming a hole disposed through the stud thickness.

16 . The antenna array of claim 15 , wherein the horn receptacle of the dielectric insert is configured to receive the alignment horn to aid in maintaining positioning of the radiating element;

wherein at least a portion of the horn receptacle comprises a conical frustum geometry; and

wherein the alignment horn further comprises a shaft configured to be disposed within the horn receptacle.

17 . The antenna array of claim 16 , wherein the shaft of the alignment horn comprises a conical frustum geometry comprising a narrow end having a relatively smaller diameter and a wide end having a relatively larger diameter;

wherein the conical frustum geometry of the horn receptacle comprises a narrow end having a relatively smaller diameter and a wide end having a relatively larger diameter;

wherein the alignment horn is disposed within the horn receptacle such that the narrow end of the alignment horn forms a compression fit against the narrow end of the horn receptacle; and

wherein the alignment horn is disposed within the horn receptacle such that the wide end of the alignment horn forms a compression fit against the wide end of the horn receptacle.

18 . The antenna array of claim 16 , wherein the detent end of the alignment horn is configured to be pressed through the horn receptacle and disposed on a distal surface of the stud, and wherein the distal surface of the stud is a side farthest from the radiating element of the antenna array.

19 . The antenna array of claim 15 , wherein the dielectric insert further comprises a plug attached to the stud;

wherein the plug is disposed adjacent to the horn receptacle; and

wherein the plug is configured to maintain positioning of the radiating element.

20 . The antenna array of claim 19 , wherein the plug comprises four sides disposed substantially perpendicular to a planar surface of the stud; and

wherein a dimension of each of the four sides is optimized for maintaining positioning of four radiating elements arranged in an orthogonal pair arrangement.

21 . The antenna array of claim 15 , wherein the horn receptacle of the dielectric insert is configured to receive the alignment horn to aid in maintaining positioning of the radiating element;

wherein at least a portion of the horn receptacle defines the hole with a cylindrical geometry;

wherein at least a portion of the alignment horn comprises a cylindrical geometry; and

wherein the alignment horn is disposed within the horn receptacle such that a slip fit is formed between an outer wall of the alignment horn and an inner wall of the horn receptacle.

22 . The antenna array of claim 15 , further comprising an adhesive disposed between a surface of the dielectric insert and a surface of the antenna array for adhering the dielectric insert to the antenna array such that the dielectric insert maintains positioning of the radiating element.