Radome Manufacturing: Composite Antenna Covers and RF-Transparent Structures

What Are Radomes?

A radome is a protective cover designed to shield antennas, radar systems and communication equipment without significantly blocking radio-frequency signals. The word “radome” comes from “radar” and “dome”, but today radomes are used not only for radar, but also for GPS, GNSS, telemetry, SATCOM, LTE, RF communication and other antenna systems.

The main purpose of a radome is to protect sensitive electronic equipment from wind, rain, dust, UV exposure, vibration, impact, chemicals and harsh environmental conditions. At the same time, the material must remain electrically non-conductive and RF-transparent enough for the antenna to operate correctly.

Unlike regular covers or housings, radomes are not only mechanical parts. They are functional composite structures where material selection, thickness, geometry and surface quality can directly affect antenna performance.

Where Radomes Are Used

Radomes are used in many industries where antennas or radar systems need protection.

Common applications include:

• UAVs and drones;

• aircraft and aerospace systems;

• ground vehicles and special-purpose platforms;

• marine communication and radar systems;

• military and defense equipment;

• satellite communication systems;

• GPS and GNSS antenna covers;

• telemetry and data-link systems;

• industrial wireless equipment;

• telecom and RF infrastructure;

• robotics and autonomous systems.

In UAVs and drones, radomes are especially important because they protect antennas while keeping the structure lightweight and aerodynamic. A well-designed composite radome can improve durability, reduce drag and protect critical communication systems during operation.

Types of Radomes

Radomes are designed in many different shapes and configurations depending on the antenna type, operating frequency, environmental conditions and installation method.

The most common types include:

Aircraft Nose Radomes

Large aerodynamic structures mounted on the nose of aircraft to protect weather radar systems while minimizing aerodynamic drag and RF signal attenuation.

UAV and Drone Radomes

Lightweight composite radomes designed for GPS, GNSS, telemetry, SATCOM, LTE, RF communication systems and onboard radar sensors. These radomes must combine low weight, aerodynamic efficiency and reliable RF transparency.

GPS and GNSS Antenna Covers

Compact radomes that protect navigation antennas from moisture, dust, vibration and UV exposure while maintaining stable satellite reception.

Radar Radomes

Protective enclosures for surveillance, weather, marine and military radar systems. These may range from small antenna covers to very large dome structures installed on buildings or ships.

SATCOM Radomes

Composite domes designed to protect satellite communication antennas installed on aircraft, vehicles, ships and fixed communication stations.

Marine Radomes

Weather-resistant enclosures protecting radar and satellite communication equipment from salt water, UV radiation and harsh marine environments.

Ground Vehicle Radomes

Protective antenna housings used on autonomous vehicles, military platforms, emergency vehicles and industrial machinery.

Telecom and RF Infrastructure Radomes

Radomes used to protect antennas for wireless communication systems, base stations and specialized RF equipment.

Custom Composite Radomes

Application-specific radomes manufactured according to customer requirements, including unique geometries, integrated mounting features and specialized environmental protection.

Materials Used for Radome Manufacturing

Selecting the right material is one of the most important aspects of radome design. Unlike conventional composite structures, radomes must provide both mechanical protection and minimal influence on electromagnetic wave transmission.

Different materials are selected depending on the operating frequency, mechanical requirements, environmental conditions and budget.

Fiberglass Composites

Fiberglass reinforced with epoxy resin is the most widely used material for radome manufacturing. It offers an excellent balance between RF transparency, strength, durability, corrosion resistance and cost.

Because of these properties, fiberglass radomes are commonly used for UAVs, drones, GPS antennas, communication equipment, marine electronics and industrial RF systems.

Quartz Fiber Composites

Quartz fiber composites provide even lower dielectric losses than standard fiberglass and are commonly used in high-performance aerospace, military and satellite communication applications.

Although significantly more expensive, quartz fiber offers excellent RF performance at microwave and millimeter-wave frequencies.

PTFE-Based Composites

Polytetrafluoroethylene (PTFE) composites are used when extremely low dielectric constant and minimal signal loss are required.

These materials are commonly found in high-frequency radar systems, advanced communication equipment and aerospace applications operating in microwave frequency bands.

Cyanate Ester Composites

Cyanate ester resin systems are widely used in aerospace and defense radomes because they combine excellent RF transparency with low moisture absorption, high thermal stability and outstanding dimensional accuracy.

These materials are often selected for demanding satellite communication systems and airborne radar applications.

Thermoplastic Engineering Plastics

Certain engineering plastics can also be used for radomes, especially in low-cost or compact antenna applications.

Depending on the requirements, manufacturers may use materials such as ABS, ASA, Polycarbonate (PC), Polypropylene (PP), Polyethylene (PE) or specialized RF-transparent engineering polymers.

Many of these materials are suitable for injection molding or thermoforming, allowing economical production of large quantities.

3D Printed Radomes

Additive manufacturing has become increasingly popular for rapid prototyping and low-volume production.

Technologies such as SLA, SLS, MJF and FDM enable engineers to quickly manufacture prototype radomes for testing, fit verification and early functional evaluation.

For production applications, specialized RF-transparent printing materials may be selected depending on the operating frequency and performance requirements.

Sandwich Composite Structures

Large radomes frequently use sandwich construction consisting of fiberglass skins bonded to lightweight foam or honeycomb cores.

This approach provides excellent stiffness while minimizing weight, making it ideal for aerospace and marine applications.

Carbon Fiber Structures

Carbon fiber is generally not suitable for the RF-transparent portion of a radome because it is electrically conductive and can attenuate or distort electromagnetic waves.

However, carbon fiber is often used for structural frames, mounting brackets, stiffening elements and non-RF-critical sections surrounding the radome.

Radomes Manufactured by Compositech

Compositech manufactures custom composite radomes, antenna covers and RF-transparent housings for UAVs, drones, communication systems, industrial equipment and specialized engineering projects.

We focus on manufacturing lightweight fiberglass composite radomes and antenna covers according to customer requirements, CAD models, drawings or existing parts. Our production capabilities allow us to manufacture both prototypes and small-to-medium production batches.

Depending on the project, we can produce:

• UAV radomes;

• drone antenna covers;

• GPS/GNSS antenna covers;

• telemetry antenna housings;

• RF-transparent fiberglass covers;

• custom composite enclosures;

• protective covers for communication equipment;

• prototype radomes for testing and validation.

Manufacturing Technologies We Use

At Compositech, radomes and antenna covers can be manufactured using several composite production methods, depending on the required geometry, strength, weight, surface quality and production volume.

Our technologies include:

Wet layup with vacuum bagging

- A flexible and cost-effective method for prototypes and small production runs. Vacuum bagging improves laminate quality, reduces air voids and helps create lighter and stronger parts.

Resin infusion

- A more controlled process suitable for larger or higher-quality composite structures. Resin infusion allows better fiber-to-resin ratio, cleaner laminates and improved repeatability.

Mold-based composite manufacturing

- For repeatable geometry and better surface quality, radomes can be produced in dedicated molds manufactured by CNC machining or other tooling methods.

CNC trimming and finishing

- After molding, composite radomes can be trimmed, drilled and finished according to the customer’s assembly requirements.

Painting and surface finishing

- Radomes can be supplied with protective coatings, paint or surface finishes depending on environmental and visual requirements.

Why Composite Radomes Matter

A radome is more than just a cover. It must protect the antenna mechanically while allowing the system to transmit and receive signals correctly. This makes material selection, manufacturing accuracy and process control extremely important.

Composite radomes offer an effective balance of low weight, strength, corrosion resistance, weather protection and design flexibility. For UAVs, robotics, communication systems and defense-related platforms, this combination is especially valuable.

Compositech provides manufacturing solutions for companies that need custom radomes, antenna covers and lightweight composite housings for advanced engineering applications.