Tribology coatings for mobility applications - Lesson 5: Coating solutions for radar antennas
Welcome to the last lesson of the Ionbond Summer School 2026!
Last time, we explored coating solutions for aerospace and learned how advanced surface technologies help components perform reliably in some of the most demanding environments.
Today, we want to give you an insight into a completely different field of application. Let’s explore the future of autonomous driving.
Advanced Driver Assistance Systems (ADAS)
Over the past few decades, vehicles have been continuously equipped with new driver-assistance systems. From cruise control to anti-lock braking systems and electronic stability control, these systems have become digital, sensor-based, and interconnected, allowing us to drive much more comfortably today with features such as adaptive cruise control, lane-keeping assist, and emergency braking assist.
New technological developments are making it possible to delegate more and more active driving tasks and increase the level of automated driving. To ensure these functions work safely, an increasing number of sensors is required. One component within these sensors is the waveguide. Depending on the sensor, one to three waveguides are installed per radar antenna.
Waveguides
Waveguides must meet high functional requirements, such as very high resolution and accuracy, as well as resistance to environmental influences.
In the past, waveguides were made from milled aluminum. However, due to rising demand, production is shifting to plastic, which must be functionalized through metallization. This is where coatings come into play.
Requirements for coatings of metallized PPS
First of all, the coating must provide good adhesion to the PPS substrate. This can, but does not necessarily have to, be achieved using a bonding layer.
The actual functional layer, which must exhibit high electrical conductivity, is applied on top of this bonding layer. Copper is typically used for this purpose.
To protect the functional layer and maintain its properties, a very thin corrosion-resistant layer is applied as a final step.
Since the waveguide structures are complex and critical to functionality, the requirements for layer quality and distribution are also essential.
PPS: Base material of the waveguide
Adhesion layer: Ensures reliable bonding between the substrate and the coating
High electrical conductivity layer (Cu): Provides the required electrical performance
Corrosion protection layer: Protects the functional layer against environmental influences
Mass production
As the degree of automation increases, so does the number of radar antennas and waveguides, sometimes requiring several per sensor.
To implement this large-scale production in a cost-effective manner, manufacturing optimizations are necessary. These encompass not only the production of the blank but also the coating process.
In addition to optimizing the coating thickness and eliminating the bonding layer, there is another way to increase cycle time and thus reduce costs.
Inline coating for higher efficiency
While most coating processes are carried out in batch systems, this product offers the option of using an inline machine.
The advantage of an inline machine you can see on the right.
Ionbond not only possesses technical expertise in coating technology but also has extensive experience with inline production. An inline system is available in Venlo, the Netherlands.
Continuous flow of components through the machine
which leads to higher efficiency.
Automation
These types of machines can also be automated more easily.
Let's talk about your ideas!
Would you like to learn more about this exciting topic or discuss potential ideas? Reach out through our contact form below, we would be happy to assist you.
Questions?
Discuss your challenges with André Hieke
André Hieke, Global Product Manager Mobility, will be glad to support you.
We will get back to you as soon as possible
André Hieke
Global Product Manager Mobility
André Hieke
Global Product Manager Mobility
Ionbond Summer School
Discover all our lessons on the performance-enhancing properties of tribology coatings for mobility applications
Lesson 1: How are tribology coatings designed?
Available on 4. August 2026
In this lesson, we explore how coatings for mobility applications are designed, the factors that must be considered during development, and why DLC coatings provide key advantages for specific application requirements.
Lesson 2: Highly resilient DLC coatings for extreme applications
Available on 11. August 2026
We are diving into highly resilient DLC coatings designed for demanding mobility applications where components are exposed to high loads, increased torque, changing lubrication conditions, and rough counter surfaces.
Lesson 3: Tribology coatings for hydrogen applications
Available on 18. August 2026
We'll explore challenges like corrosion resistance, long-term reliability, stable friction behaviour, and protection against hydrogen diffusion which tribological coatings face in applications involving alternative fuels.
Lesson 4: Coating solutions for aerospace
Available on 25. August 2026
We take a closer look at coating solutions for aerospace and how coating solutions help protect critical parts against wear, corrosion, oxidation, erosion, and fatigue while supporting higher efficiency and longer service life.
Lesson 5: Coating solutions for radar antennas
Available on 1. September 2026
In this lesson, we explore the future of autonomous driving and the role of radar antennas in Advanced Driver Assistance Systems. These critical components require coating solutions that combine strong adhesion, high electrical conductivity, corrosion protection, uniform layer distribution, and cost-effective manufacturing at scale.