An Integrated Shared-Aperture Active Phased Array Enabling STAR LEO Satellite Communication: Concept, Design, and Validation

This study introduces an innovative K-/Ka-band planar active shared-aperture phased array (ASAPA), advancing low earth orbit (LEO) terminal design through synergistic innovations in shared-aperture topology and three-dimensional (3D) integration. Breaking from conventional shared-aperture topologies plagued by cross-band interference and radiation pattern distortion, we propose a partial-element-reuse-based (PER) topology that strategically repurposes 50% of dual-band dual-polarized elements for simultaneous transmit and receive (STAR) operation. This configuration eliminates active element pattern distortion while achieving a reduction in element count, enabling wide-angle beam scanning essential for dynamic satellite tracking. Furthermore, a sandwich-structured printed circuit board (PCB) lamination method is further employed to streamline integration by partitioning functional modules into antenna, coupler, and active circuit layers interconnected via ball grid array (BGA) technology. This 3D integration strategy simplifies vertical interconnects, minimizes PCB layer requirements, and enhances thermal dissipation through embedded air gaps. Experimental results validate robust beamforming performance across ±60° scanning ranges for both transmitting and receiving arrays, achieving high transceiver isolation and signal integrity, which are imperative for high-capacity satellite links. By addressing key bottlenecks in LEO terminal design, the proposed innovations can accelerate the deployment of energy-efficient, cost-effective satellite networks, thus advancing the 6G vision of ubiquitous global connectivity.