Abstract
A smooth-walled horn is often preferred over a corrugated horn due to easier and cheaper manufacturing. By optimizing the profile of the horn it is possible to obtain low cross polarization over a broad bandwidth. In this paper a very efficient method of profile definition, analysis and optimization for a stepped profile horn is described and applied to the design of a 20/30 GHz feed horn suited for a satellite broadcasting system with return link (DVB-RCS). The horn design is manufactured by plastic injection molding and metallization, as part of an ESA project

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