Flexible Phased Array Sheets: A Techno-Economic Analysis

Phased arrays have enabled advances in communications, sensing, imaging, and wireless power transfer. In all these applications, large apertures enable higher power, higher data rates, higher resolution, and complex functionalities, but are elusive owing to a correspondingly large cost, mass, and physical size. Flexible phased arrays (FPAs) show potential in breaking this trade-off. Their thinness and extremely low mass allow FPAs to be folded, rolled, or otherwise compressed into smaller sizes, thus enabling new regimes of transport and entirely new applications currently not possible. Though a number laboratory prototypes of FPAs have been constructed, the economics of large-scale FPA production has yet to be explored. This paper presents a model FPA architecture and a cost model for producing it at large-scale. The estimate of the per-unit-area cost is bounded by a three-tiered approach. The cost model projects a "middle" estimate for FPA production at $89 per square meter. Estimates for aerial mass density and startup cost are also discussed. This cost model demonstrates that an FPA can be produced at an efficient price point and can potentially replace existing solutions for space, communications, and vehicular applications that demand lightweight, portability, and durability in extreme conditions.