Loss is the issue.  Teflon substrate is used above 6 gHz.  Specifically the 
“loss tangent”

Sent from my iPhone

> On Nov 29, 2020, at 1:42 PM, Ken Hohhof <af...@kwisp.com> wrote:
> 
> 
> I thought patch antennas couldn’t be cheap FR4 and had to be some expensive 
> PTFE/fiberglass substrate or something.  Maybe that depends on frequency.
>  
> From: AF <af-boun...@af.afmug.com> On Behalf Of Chuck McCown via AF
> Sent: Sunday, November 29, 2020 2:09 PM
> To: Darin Steffl <darin.ste...@mnwifi.com>; AnimalFarm Microwave Users Group 
> <af@af.afmug.com>
> Cc: ch...@go-mtc.com
> Subject: Re: [AFMUG] YouTuber dismantles the SpaceX Starlink 'Dishy 
> McFlatface' Antenna! [V
>  
> The antenna is an array of circular patches with a parasitic patch for a bit 
> more gain.
>  
> The whole array is not one huge phased array but a cluster of smaller groups 
> of patches. 
>  
> I can have that antenna PCB made for probably $20.  It is just a normal pcb.  
> All the chips that have made it possible for you to have a phased array on 
> the front bumper of your car can easily make this happen. 
>  
> Phase shifting RF in a chip is no longer difficult nor expensive.  There are 
> a bunch of them though, so just the sheer number of chips will make it more 
> expensive but it is surly to be custom silicon. 
>  
> From: Darin Steffl
> Sent: Sunday, November 29, 2020 12:27 PM
> To: AnimalFarm Microwave Users Group
> Cc: Chuck McCown
> Subject: Re: [AFMUG] YouTuber dismantles the SpaceX Starlink 'Dishy 
> McFlatface' Antenna! [V
>  
> Most guesses are upwards of $2,500 to manufacturer. Phased array antennas are 
> very expensive and before they put a lot of effort into reducing cost, most 
> said minimum $10k for this type of antenna.
>  
>  
>  
> On Sun, Nov 29, 2020, 12:36 PM Chuck McCown via AF <af@af.afmug.com> wrote:
> That antenna array alone is probably costing them $20 and another $20 of 
> chips on it.  I am guessing it is north of $100 to make. 
>  
> From: Ken Hohhof
> Sent: Sunday, November 29, 2020 11:28 AM
> To: 'AnimalFarm Microwave Users Group'
> Subject: Re: [AFMUG] YouTuber dismantles the SpaceX Starlink 'Dishy 
> McFlatface' Antenna! [V
>  
> What do you estimate it would cost them to manufacture in large quantities?  
> People are probably assuming it’s a $10 item at some point, but it looks 
> expensive to me, even at scale.
>  
> From: AF <af-boun...@af.afmug.com> On Behalf Of Chuck McCown via AF
> Sent: Sunday, November 29, 2020 11:49 AM
> To: AnimalFarm Microwave Users Group <af@af.afmug.com>
> Cc: ch...@go-mtc.com
> Subject: Re: [AFMUG] YouTuber dismantles the SpaceX Starlink 'Dishy 
> McFlatface' Antenna! [V
>  
> Clever motor assembly.   Be fun to use that same mechanism for a solar panel. 
>  I may have to give that a try. 
> So, it does steer mechanically.  Almost has to to maximize the gain. 
>  
> Looks like roughly 2000 patches. 
> Looks like roughly 500 chips feeding them.  So a 4 patch array fed by a 
> T/R-LNA - power amp.  4-6 of those clusters fed into a larger chip that 
> probably does the phasing for steering.
>  
> So the antenna is just a whole lot of simple in a very massive scale. 
>  
>  
>  
> From: Jaime Solorza
> Sent: Sunday, November 29, 2020 8:24 AM
> To: AnimalFarm Microwave Users Group
> Subject: [AFMUG] YouTuber dismantles the SpaceX Starlink 'Dishy McFlatface' 
> Antenna! [V
>  
> https://www.tesmanian.com/blogs/tesmanian-blog/starlink-teardown 
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