Patent No. EP4473616 (titled "Low-Cost Radome Materials And Fabrication Processes") was filed by Viasat on Feb 24, 2023. The application was issued on Oct 29, 2025.
A radome comprises a structural layer and an RF matching layer disposed on at least one side of said structural layer. The structural layer consists of a fiber reinforced thermoplastic composite comprising a fiber reinforcement and a thermoplastic resin, where the resin content is between 25 percent and approximately 60 percent by weight. The RF matching layer possesses a first dielectric constant value lower than the dielectric constant value of the structural layer. The design balances structural integrity—necessary for resisting aerodynamic loading, weather, and ballistic strikes—with RF performance to minimize signal attenuation, reflections, and distortions. This thermoplastic composite approach provides manufacturing and cost efficiencies over traditional A-sandwich structures or labor-intensive thermoset polymers.

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