Corrugated Vivaldi Antenna Architecture for 5G CubeSat Communications: Sub-6 GHz Experimental Validation and Millimeter-Wave Simulation Scaling

This paper presents a corrugated Vivaldi antenna architecture targeting sub-6 GHz and millimeter-wave frequency bands for 5G CubeSat applications, combining experimental validation at sub-6 GHz with a simulation-based scaling study at 26.5 GHz. Existing CubeSat antenna designs either target a single frequency band or rely on complex metamaterial structures incompatible with nanosatellite fabrication constraints. To address this gap, a single-element corrugated Vivaldi antenna measuring 90 mm × 80 mm is designed, fabricated on FR-4 substrate, and experimentally validated at 3.5 GHz, confirming a wide impedance bandwidth of 2.75 GHz and a peak gain of 9.6 dBi. The strong agreement between CST Studio Suite simulations and measurements validates the electromagnetic solver configuration, which is subsequently applied, as a simulation-based design study, to a geometrically scaled version on Taconic RF-60A substrate operating at 26.5 GHz. The miniaturized single-element version achieves a simulated 17 GHz ultra-wideband response and 6 dBi gain in a 7.32 mm × 6.32 mm footprint. Two- and four-element array configurations at 26.5 GHz demonstrate systematic simulated gain progression to 9 dBi and 13 dBi, respectively, with beamwidth narrowing from 49∘ to 30∘. All 26.5 GHz designs are simulated with lossy copper metallization (σ=5.8×107 S/m) and are entirely simulation-based; experimental mmWave validation is a designated target for future work. These results establish a validated design and scaling roadmap for corrugated Vivaldi antennas spanning sub-6 GHz and millimeter-wave bands, offering a cost-effective and CubeSat-compatible solution for high-data-rate inter-satellite communication links.