Compact Reconfigurable Industry-Level Ka-band Switch Matrix Payload Module for Geostationary Satellite Operation

In this paper we describe the development of a compact and lightweight reconfigurable 4x4 switch matrix module for geostationary satellite communications in Ka-band (17 ... 22 GHz), where signal routing becomes more and more relevant. The module is based on a space-qualified low-temperature co-fired ceramic multilayer technology. Following a successful on-orbit verification aboard a low-earth orbit satellite mission, the switch matrix has undergone major design revisions, aiming at an industry-scale manufacturability without compromising the advanced functional performance. By applying a system-in-package approach including automated hybrid assembly, a fully operational breadboard version has been developed, which upon further space qualification steps is intended to become part of a reconfigurable input multiplexer aboard the geostationary Heinrich Hertz satellite. Combining a ceramic package, an organic multilayer interface, wire-bonded coaxial connectors into an aluminum housing, the dimensions measure 126 mm x 87 mm x 11 mm with a weight of 193 g, corresponding to a reduction of 60 % in volume and 40 % in mass compared to a previous electronic version, and orders-of magnitude better than coaxial switch matrices.