RF Windows

RF Windows for Microwave and High-Frequency Systems

Safeguarding the most critical devices through comprehensive RF signal integrity and precision fabrication.

At Elcon Precision, we manufacture custom RF Windows using advanced ceramic-to-metal sealing and vacuum brazing techniques, supporting mission-critical applications in aerospace, defense, space systems, and scientific instrumentation. Our RF windows are manufactured using advanced processes to ensure reliability and performance. With tight mechanical tolerances, exceptional RF transparency, and hermetic performance, our RF Windows serve as the essential interface between harsh environments and high-frequency electronics.

Elcon Precision offers both custom and production RF windows to meet the needs of a wide number of applications and industries, and consistently looks for opportunities to expand our product range and RF window solutions.

What Is an RF Window?

An RF (Radio Frequency) Window is a dielectric barrier that is primarily used to allow RF or microwave power to pass through with minimal reflection or signal loss, while sealing a pressurized or vacuum enclosure. These components are critical in systems where signal integrity and environmental isolation must coexist, primarily in the following fields:

Radar & Missile Guidance Systems
Satellite Communication Payloads
Waveguides and Vacuum Chambers
Particle Accelerators & Cyclotrons
Linear Accelerators

How They Work:

Constructed from RF-transparent ceramics like alumina or sapphire
Typically housed within waveguides or assemblies to ensure proper placement and protection
Brazed or sealed to metal frames or flanges for hermeticity
Engineered for low dielectric loss, thermal stability, and mechanical durability

Materials & Sealing Technologies

At the core of Elcon’s RF Window solutions is our expertise in ceramic metallization, coupled with ceramic-to-metal sealing. Our process ensures hermetic, high-integrity joints that withstand thermal cycling, vibration, and environmental stress with minimal loss to performance.

Elcon’s advanced materials and advanced sealing manufacturing processes, like working with sapphire, are designed to meet the stringent requirements across various industries.

Dielectric Materials:

Alumina (Al₂O₃): High strength, low loss, most commonly used
Sapphire: Ultra-low dielectric loss, high-end aerospace and space use
Zirconia toughened alumina (ZTA)

Sealing Materials:

Kovar, Titanium, Stainless Steel: Matched for thermal expansion compatibility
Gold,Copper, CuSil, Silver-Based Brazes: Vacuum-tight seals for extreme environments

Elcon’s Advantage: All brazing, ceramic processing, and sealing operations are performed in-house under stringent quality controls, enabling rapid prototyping and high-volume production.

Applications & Industries Served

RF Windows from Elcon Precision support a variety of advanced systems across industries:

Aerospace & Defense: Waveguide windows, radar front ends, RF-transparent protective barriers
Space Systems: Satellite transponders, communication arrays, microwave payloads
Scientific Research: Vacuum chambers, particle accelerators, instrumentation enclosures

Elcon Precision’s Capabilities

With over 50 years of experience in precision ceramic-metal fabrication, Elcon Precision offers unmatched versatility for custom RF Windows:

Sapphire metallization
Alumina metallization
Custom Ceramic-to-Metal Assemblies (flat, domed, conical)
Hermetic Sealing via high-temperature brazing and welding
Tight Tolerances: surface flatness, thickness, and alignment precision
ISO 9001:2015 & ITAR Registered
In-House Ceramic Processing, Metallization, and Brazing
High-Frequency Testing & Inspection (S-parameter, leak, and thermal cycling)
Can provide specialized engineering support, including thermal simulation, electromagnetic and mechanical design, and custom assembly configurations

Elcon’s cleanroom assembly environments and rigorous documentation ensure that all products are properly manufactured and compliant with aerospace and defense requirements.

Technical Specifications

Parameter	Typical Range
Window Diameter	0.25” to 6.0”+ (custom on request)

Custom specs and test data available upon request

Proper impedance matching in RF window assemblies is critical to minimize reflection and insertion loss, ensuring optimal performance. Elcon’s RF windows are designed for long operational times, providing reliable performance over extended periods.

Why Choose Elcon for RF Windows?

Here at Elcon Precision, we are a trusted partner for defense contractors, aerospace OEMs, and scientific research organizations that demand performance, reliability, and design flexibility. Our in-house capabilities allow us to tightly control every step of RF Window fabrication, from material selection to final hermetic sealing and electrical testing.

Decades of expertise in high-frequency ceramic-metal solutions
Rapid prototyping to full-scale production
Application-specific engineering support
Mission-critical quality for extreme environments

For more information or technical guidance regarding RF windows and related solutions, please contact Elcon.