Flexible Seamless Waveguide
Flexible Seamless Waveguide offers smooth internal surfaces for low insertion loss and high reliability in microwave transmission systems including radar antennas, satellite communication networks and mmWave systems.
Flexible Seamless Waveguides for Zero-Leakage RF Systems
AO Microwave’s flexible seamless waveguides are designed to connect misaligned components while providing zero RF leakage. Constructed from a continuous, thin-walled corrugated metal tube made of premium brass or high-elasticity beryllium copper, these guides allow for bending (E-plane and H-plane) but cannot be twisted. Protected by a vulcanized, weather-proof neoprene or silicone jacket, our seamless waveguides achieve low insertion loss and an exceptional static VSWR of < 1.10:1 to 1.15:1.
Because they are fabricated from a single continuous tube with no seams, these guides offer excellent RF shielding and lower insertion loss than twistable types. They are ideal for sensitive receiver front-ends, high-power transmitter paths, and vacuum testing setups where RF leakage must be avoided.
| Part No | Frequency/GHz | VSWR (Max) | IL dB/m (Max) | Average Power/KW (Max) | Peak Power/KW(Max) | Bend Radius E/mm (Min) | Bend Radius H/mm (Min) | Flange Type |
|---|---|---|---|---|---|---|---|---|
| AO284-WFSSXPPC | 2.60-3.95 | 1.1 | 0.08 | 10 | 2000 | 75 | 140 | UDR32 |
| AO229-WFSSXPPC | 3.30-4.90 | 1.1 | 0.08 | 8 | 1550 | 54 | 83 | UDR40 |
| AO187-WFSSXPPC | 3.95-5.85 | 1.1 | 0.12 | 6.5 | 1250 | 49 | 76 | UDR48 |
| AO159-WFSSXPPC | 4.90-7.05 | 1.12 | 0.17 | 6 | 1100 | 41 | 57 | UDR58 |
| AO137-WFSSXPPC | 5.85-8.20 | 1.12 | 0.21 | 5 | 500 | 38 | 53 | UDR70 |
| AO112-WFSSXPPC | 7.05-10.0 | 1.12 | 0.25 | 4 | 315 | 36 | 46 | UBR84 |
| AO90-WFSSXPPC | 8.20-12.4 | 1.12 | 0.37 | 3 | 180 | 32 | 38 | UBR100 |
| AO75-WFSSXPPC | 10.0-15.0 | 1.12 | 0.49 | 1.5 | 140 | 16 | 32 | UBR120 |
| AO62-WFSSXPPC | 12.4-18.0 | 1.15 | 0.62 | 1 | 90 | 18 | 32 | UBR140 |
| AO51-WFSSXPPC | 15.0-22.0 | 1.25 | 1.23 | 0.5 | 70 | 14 | 25 | UBR180 |
| AO42-WFSSXPPC | 18.0-26.5 | 1.25 | 1.23 | 0.3 | 39 | 14 | 25 | UBR220 |
| AO34-WFSSXPPC | 22.0-33.0 | 1.35 | 1.44 | 0.2 | 30 | 11 | 24 | UBR260 |
| AO28-WFSSXPPC | 26.5-40.0 | 1.35 | 2.05 | 0.15 | 20 | 11 | 24 | UBR320 |
| AO22-WFSSXPPC | 33.0-50.0 | 1.4 | 4.1 | 0.075 | 12 | 11 | 24 | UG-383/U |
Understanding Seamless Corrugated Waveguide Physics & Shielding
Flexible seamless waveguides are constructed from a continuous, thin-walled metal tube made of brass or beryllium copper, which is mechanically corrugated into a continuous series of ring-shaped or helical convolutions. Because the tube is continuous with no joints or seams, it provides complete RF shielding with zero leakage and lower insertion loss compared to helically wound twistable waveguides.
Zero Torsional Tolerance
These seamless corrugated tubes cannot be twisted. Any torsional twist can shear the convolutions and cause RF failure.
Managing Spring-back Forces
During installation, support the waveguide with clamps to avoid transferring the mechanical load onto delicate system flanges.
Target Applications & Operational Advantages
By providing seamless metal shielding and zero RF leakage, our flexible seamless waveguides deliver critical performance advantages in sensitive and high-power applications:
Sensitive Receiver Front-Ends (Radio Astronomy & EW)
Function: Connects low-noise amplifiers (LNAs) to horn antennas or mixers in critical receiving paths.
Advantage: The seamless corrugated structure provides complete RF shielding, eliminating external EMI ingress and maximizing signal-to-noise ratio (SNR) for weak signal detection.
High-Power Transmitter Plumbing
Function: Routes high-power pulsed/CW signals from transmitter tubes (e.g., magnetrons, TWTs) to antennas.
Advantage: Perfect RF shielding prevents leakage of hazardous high-power fields, protecting adjacent sensitive electronics from interference, while the seamless metal body handles high power density without breakdown.
UHV Testing & Cryogenic Chambers
Function: Transmits RF test signals into sealed vacuum or cryogenic testing chambers.
Advantage: The seamless corrugated structure avoids gas-trapping seams, eliminating outgassing (meeting NASA low-outgassing requirements) and maintaining stable mechanical flexibility at cryogenic temperatures.
Flexible Seamless Waveguide FAQs
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