Vitesse Systems, a leading provider of thermal management, antenna, and power distribution solutions for critical defence and space applications, has announced the completion of a significant expansion of its additive manufacturing capability. The multi-million-dollar investment includes the installation of two additional additive manufacturing machines and coincides with the delivery of what the company believes to be one of the largest additively manufactured satellite antennas in history.
The expanded additive manufacturing capability supports Vitesse’s growing portfolio of complex fully integrated thermal and microwave solutions. This latest investment reinforces the company’s commitment to leveraging advanced manufacturing technologies to meet the increasingly demanding requirements of defence and space applications, where performance, weight, and size optimisation are critical factors.
Expansion of Additive Manufacturing Capability
Since installing its first additive machine in 2021, Vitesse Systems has fundamentally reimagined its approach to antenna design, particularly for applications where mass, size, and performance are critical considerations. The company’s additive manufacturing capability enables a layer-by-layer construction process that eliminates unnecessary internal features that traditionally served only structural purposes.
“Additive manufacturing offers distinct advantages that we have been able to leverage to enhance the design of our offerings. Since installing our first additive machine in 2021, we have completely rethought our approach to designing certain types of antennas. This is particularly beneficial for space applications where mass and size are critical, and for ground applications where operating over a broad range of frequencies is increasingly important for both defence and civil applications.”
– Richie Dart, General Manager at Vitesse Systems
The most recent demonstration of this enhanced additive manufacturing capability is the delivery of a highly complex space antenna comprising 1,600 individual additive RF components. By collaborating with the customer from the concept stage, Vitesse was able to combine its space heritage with additive manufacturing benefits to reduce the overall size and mass of the antenna by 30%, optimise RF performance, and deliver the completed system in less than two years.
Meeting Accelerated Defence and Space Market Demands
The expansion of Vitesse’s additive manufacturing capability responds directly to changing market dynamics in the defence and space sectors. Development timelines have compressed significantly while performance requirements have increased, driven by the reality of connected battlefields and the proliferation of satellite constellations and interconnected platforms.
For ground-based antennas, Vitesse has successfully integrated additive manufacturing with existing production processes to create systems with broader capabilities. This approach enables customers to communicate with airborne and space-based assets across a wide range of frequencies and orbits, all within a single antenna system.
“Our customers require solutions within increasingly shorter timeframes, often weeks, not months,” noted Dart. “Our additive capability, combined with our RF expertise and in-house testing capabilities, allows us to exceed our customer expectations.”
Strategic Investment in Advanced Manufacturing
The enhancement of Vitesse’s additive manufacturing capability is part of a broader strategic investment in meeting growing demand for high-performance antenna and thermal management solutions. Over recent years, the company has expanded its engineering, manufacturing, and test capabilities to address fundamental changes in how military programs are procured.
“Expanding our additive manufacturing capacity is part of a broader investment strategy to meet the growing demand for high-performance antennas. In response to changing requirements, we have had to rethink how we design, manufacture, and test our antennas. Additive manufacturing, combined with our in-house design and testing capability, allows us to significantly reduce the amount of time it takes from design concept to reality.”
– Matthew Alty, CEO of Vitesse Systems
The expanded additive manufacturing capability enhances Vitesse’s ability to deliver innovative solutions that meet the exacting requirements of these demanding applications, reinforcing its position as a leading provider of thermal and microwave solutions for the defence and space sectors.
With over 55 years of industry experience, Vitesse Systems continues to position itself as a trusted partner in the aerospace and defence industries. The company specialises in the design, build, and test of critical solutions for electronic warfare, radar, and next-generation communications across air, ground, sea, and space environments.
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