Scaling RF-Transport Radome Production for Kymeta’s U8 Terminal

Client: Kymeta

Focus: Advanced Manufacturing | Assembly | Prototype-to-Production Support

Overview

Kymeta required a strategic manufacturing partner capable of supporting the full lifecycle of their U8 Radome Terminal program from early-stage prototyping through production scale.

The Fi Company partnered closely with the Kymeta team to help develop scalable assembly solutions, support rapid design evolution, and maintain critical product performance standards throughout the manufacturing process.

The result was a collaborative manufacturing approach designed to support innovation, scalability, and long-term production success.

The Challenge

The U8 Radome Terminal presented a highly technical manufacturing challenge requiring precision, adaptability, and repeatability across development and production phases.

Key project objectives included:

• Developing a repeatable, scalable assembly process for a complex multi-component structure to meet key metrics of performance
• Maintaining RF transparency and performance integrity across materials and processes
• Supporting rapid design iterations without delaying product launch timelines
• Identifying cost reduction opportunities without compromising performance

As the product evolved, the manufacturing strategy needed to evolve alongside it, balancing speed, quality, and technical precision.

Our Approach

Prototype-to-Production Collaboration

The Fi Company worked alongside Kymeta throughout the product lifecycle, helping bridge the gap between prototype refinement and scalable manufacturing readiness.

The collaboration included:

• Assembly process development
• Manufacturing optimization
• Product scalability planning
• Design iteration support
• Cross-functional coordination focused on efficiency and quality consistency

Manufacturing & Assembly Execution

Special attention was given to preserving structural integrity and RF performance throughout the assembly and manufacturing process while improving repeatability and long-term production efficiency.

Through collaborative problem solving and hands-on manufacturing expertise, The Fi Company helped support a smoother transition from development into scalable execution.

The Results

Advanced Thermoforming and Fabrication:

• Leveraged large-format thermoforming capabilities to produce high-quality Radome components with tight dimensional control.
• Supported IP66 system rating 

Proprietary Assembly Process:

• Developed a proprietary assembly process that ensures repeatability, structural integrity and alignment to critical features, all while improving cycle times by 600% compared to the prototype phase.
• 100% RF testing achieving a 99.99% pass rate 

Cost Optimization:

• Identified alternative manufacturing approaches for mating components, reducing overall system cost.

Rapid Iteration Support:

• Enabled fast prototype cycles to support on-going design validation and accelerate product readiness.
• Design flexible assembly station to adjust to product evolution

Customer Feedback

“I just wanted to say that I am so impressed with how your sample Radome looks and feels. Nice job! Thank you for all the effort you all have gone through to create such a nice part! I’m looking forward to seeing the assembly go together and future parts from you.” – Lead Quality Engineer, Kymeta

“Folks are very pleased with your work.” – Director, Supply Chain & Procurement, Kymeta

“The Fi Company is an integral part of Kymeta’s success.” – Buyer, Kymeta

About Kymeta

Kymeta is a cutting-edge satellite communications company delivering solutions for the next generation of mobile connectivity. Kymeta is unlocking the potential of satellite, combined with cellular networks, to offer solutions that are low-profile, lightweight, easy to install, and virtually maintenance free.

About The Fi Company

The Fi Company’s plastics division is a contract manufacturer specializing in advanced plastics manufacturing including thermoforming, reaction injection molding (RIM), high performance coatings, and electromechanical assembly.  Fi partners with customers from initial concept through production to deliver high-quality, cost-effective solutions for complex applications.

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