SARC | A Multi-Functional PI Film R2R Coating Platform Built for Satellite Communications and Aerospace Applications

A PI Film R2R Coating Platform Built for Satellite Communications and Aerospace Applications

Low Earth Orbit (LEO) satellite constellations, satellite ground receiving stations, automotive radar, 5G/6G millimeter-wave communications, defense aerospace communications — these contemporary and next-generation communication technologies share common characteristics: high-frequency signal transmission, precision antenna arrays, and demanding environmental durability. From 24 GHz automotive radar, 28 GHz 5G mmWave, to 60+ GHz satellite communication bands, the higher the signal frequency, the more demanding the requirements on antenna component coating quality. At the same time, satellite and aerospace applications must withstand extreme environments including space radiation, thermal cycling, and vacuum — substrates must possess top-tier heat resistance and long-term stability.

The Dah Young Vacuum SARC (Satellite Antenna R2R Coater) is a large-width R2R sputtering system optimized specifically for PI (Polyimide) substrate satellite communications and high-frequency RF applications. The SARC employs HiPIMS high-power impulse technology, PI high-heat-resistance substrate handling capability, seed layer + primary conductive layer multi-stage architecture, and high-cleanliness process design — while also supporting optical film integration on PI film, enabling RF high-frequency + optical function integrated multi-functional satellite components. It delivers industry-leading PI film mass production solutions for the satellite communications industry, aerospace defense, and 5G/6G module manufacturers.

HiPIMS High-Ionization Technology | Key to High-Frequency Signal Integrity

High-frequency RF applications place two core requirements on conductive layers — low surface roughness and low interfacial impedance. Surface roughness directly impacts skin effect losses in high-frequency signals; rough surfaces substantially increase signal transmission impedance. Interfacial impedance determines the degree of signal reflection at the antenna-substrate interface; any minor interfacial defect amplifies into severe signal integrity problems at millimeter-wave frequencies.

The SARC comes standard-equipped with HiPIMS (High Power Impulse Magnetron Sputtering) high-power impulse power supply. Through high-ionization-rate metal plasma, it forms atomic-level dense conductive layers on PI substrate surfaces. The copper / silver film deposited via HiPIMS exhibits extremely low surface roughness and excellent interfacial density — reducing millimeter-wave-band signal transmission loss by over 30% compared with conventional DC sputtering, fully meeting the demanding standards of LEO satellite, 5G mmWave, automotive radar, and other high-end RF applications.

PI High-Heat-Resistance Substrate Optimization | Addressing Space and Aerospace Extreme Environments

PI polyimide film possesses top-tier heat resistance (continuous use temperature up to 260°C and above), excellent dimensional stability, and outstanding space radiation tolerance — making it an irreplaceable core substrate for satellite antennas and aerospace communication components. However, PI's low surface activity and strong chemical inertness commonly challenge conventional sputtering processes in adhesion and thickness uniformity.

The SARC delivers deep process optimization for PI substrates — plasma pre-treatment improves PI surface activity, seed layer precision control provides adhesion transition, and HiPIMS primary conductive layer ensures dense interfacial structure. This dedicated process design enables the SARC to deposit high-quality conductive layers and optical films meeting satellite aerospace application requirements on PI substrates — helping customers break through traditional process bottlenecks of PI substrates.

Optical Film Integration on PI | Key Capability for RF + Optical Multi-Functional Components

One important trend in next-generation satellite and aerospace applications is RF + Optical dual-function integrated components — on the same PI substrate, both high-frequency antenna RF conductive function and optical film integration are needed to achieve solar spectrum selective reflection, laser communication optical path control, thermal radiation management, or specialty band sensing. Conventional processes require completing RF and optical separately on different equipment — process-intensive, costly to integrate, and exposed to contamination and alignment accuracy risks during substrate transfer.

The SARC breakthrough integrates RF conductive layer and optical thin film dual coating capabilities — within a single machine on a single PI substrate, sequentially completing high-adhesion deposition of the conductive metal layer and precision stacking of multilayer optical films. This technology integration capability provides satellite antenna customers with an industry-rare one-stop RF + Optical integrated process — substantially simplifying the production workflow of next-generation multi-functional satellite components, while effectively reducing contamination risk and improving overall yield. For the satellite and aerospace industries pursuing component integration, weight reduction, and rapid mass production, the SARC delivers the industry's most complete PI film multi-functional coating solution.

High-Cleanliness Process Design | Reliability Assurance for Satellite and Aerospace Applications

Satellite communication components must maintain long-term reliable operation under extreme space environment conditions (thermal cycling, radiation, vacuum). Any particle contamination from the process environment or film defect may amplify into catastrophic failure under demanding usage conditions. The SARC targets high cleanliness from the equipment design stage — chamber uses low-particle-release materials, load-lock zones employ high-cleanliness design, and all workpiece-contact components undergo rigorous cleaning procedures.

The SARC's high-cleanliness process design, paired with Dah Young's proprietary inline electrical measurement capability, validates critical performance parameters of conductive layers and optical films immediately after each batch process — achieving real-time process quality control. For applications demanding extremely high long-term reliability such as satellite aerospace, defense communications, and automotive radar, the SARC provides industry-rare process-level reliability assurance.