Low cost and high performance millimeter-wave phased array antennas have been demanded in recent years due to increasing millimeter-wave applications in highspeed mobile communications, broadband wireless LAN/PAN (WLAN/WPAN), automotive collision avoidance radars, and so on. Several types of millimeter-wave antennas and components have been proposed for these systems. For example, plastic waveguide structures, which are composed of hollow liquid crystal polymer (LCP) and plated copper [1], [2], have been reported in order to reduce the cost for mass-production scheme. However, the phased array antennas are difficult to form their complex configurations and difficult to obtain low-loss characteristics as well. This paper presents millimeter-wave waveguide-type phased array antennas using low-loss engineering plastics not only to reduce cost but also to obtain high performances with complex configurations. That is a Cyclo-Olefin Polymer (COP) waveguide horn array antenna which is fabricated by injection molding process [3].
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