Communications for demanding environments
Historically, Filtronic’s three main areas of activity have been mobile telecommunications infrastructure, defence and aerospace, and public safety. As part of its diversification strategy, the company is deploying its transceiver modules in new applications, of which the space sector currently presents the biggest opportunity so is discussed in more detail.
Mobile telecommunications infrastructure market
Enabling true 5G networks
Exhibit 2: Morpheus transceiver module
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Mobile phone cell sites are connected to the fibre backbone using either fibre links or wireless backhaul links. Initially the wireless links operated in the licensed microwave bands between 6GHz and 42GHz (see Exhibit 1). As the data demands on telecommunication networks have risen, the capacity provided by backhaul links has had to increase as well. This has been achieved by using links operating at higher frequencies so more data can be transmitted per second, most recently by using significant extra bandwidth in the lightly licensed E-band (71–76GHz/81–86GHz).
Filtronic has been designing and manufacturing E-band transceivers, devices that both transmit and receive wireless signals, for over a decade. The latest family, the Morpheus range, was launched in February 2020 and deploys a new generation of higher-power amplifier MMICs designed in-house by Filtronic. This gives Filtronic an immediate power advantage over amplifiers produced by competitors, which rely on standard MMICs from chip vendors. The first modules in the range, Morpheus II, were 20% smaller and 50% lighter than the Orpheus modules, which were launched in 2016. Both generations of modules are designed for easy integration into OEMs’ outdoor units (ODUs), giving OEMs the advantage of a rapid time to market while requiring minimal engineering resource. Additionally, both the Orpheus and Morpheus modules have been qualified for deployment in the latest radio platforms specifically developed for 5G applications and have been field proven in wide-bandwidth, high-capacity applications up to 10Gbp per channel. Filtronic’s lead telecoms OEM customer, which had been deploying Orpheus modules in its 5G backhaul equipment, started to deploy Morpheus modules in volume during H121. In September 2022, the company launched the Morpheus X2 module, offering 3dB extra linear transmit power output compared to Morpheus II for the same footprint, increasing the line of sight of the ODU by up to 12km. In April 2023, the company signed a $1.1m/£0.9m production contract with a leading 5G telecom infrastructure provider to supply Morpheus X2 modules through the course of FY24, with further production volumes forecast for FY25.
Early 5G networks augmented the capacity of existing 4G long-term evolution (LTE) networks through the use of carrier aggregation techniques, which enabled the basic 5G New Radio (5G NR) phase 1 performance requirements to be met. More recent network rollouts deliver the full 5G NR phase 2 performance. These networks require higher transmission capacities, which can only be achieved by moving to the higher frequencies. The shift to full high-performance E-band is therefore beneficial to Filtronic, which is able to offer equipment at this frequency. For example, demand was boosted recently by network providers building inventory to support the construction of networks in India following the regulatory authority there finally approving the release of E-band and V-band licences in August 2022. The shift to E-band is also beneficial because more cell sites are needed to provide the same coverage in a network because higher-frequency wireless links cover shorter distances.
Filtronic is already preparing for a move into even higher frequency bands: W-Band (92–114.5GHz) and D-Band (130–175GHz). Moving to these higher frequencies will support links capable of transmitting up to 100Gbps, which will be required as the communications industry responds to ever increasing demands for data.
Demand also linked to the proportion of radio links versus fibre links
Demand for Filtronic’s equipment also depends on the proportion of cell sites that are connected to the fibre backbone via wireless links rather than fibre. Wireless links are currently deployed in more than 50% of cell sites globally, with a much higher proportion in much of India and parts of Asia and Latin America than urban areas of the United States. Replacing existing lower-frequency wireless backhaul with fibre is not always practical or economically viable, so upgrading to E-band microwave links is the most effective way to increase capacity at these sites. In areas where there is no infrastructure in place and a fibre point of presence (PoP) is a few hundred metres away from the radio access point, the cost of adding new fibre may be significantly higher than adding a wireless link because although the cost of the fibre cable itself is reducing, this is typically a fraction of the investment required to trench and install the cable, whereas the cost to supply and install point-to-point, line-of-sight wireless links continues to reduce. Filtronic notes that current market estimates (source: The Ericsson Mobility Report) predict that by 2027, microwave will account for 65% of the installed base of backhaul connections and, based on an 11% CAGR, at least 30% of these wireless links will be high-frequency mmWave, deployed in areas of high traffic density such as airports, sports stadiums and metropolitan areas.
A report from the Dell’Oro Group published in January 2023 noted that while the main backhaul technology early in the 5G deployment cycle was fibre, it expected more deployments in future to take place in locations without accessibility to fibre as well as in countries that have traditionally favoured wireless backhaul systems. The report predicted that microwave transmission systems in E and V bands would grow by around 20% annually for the next five years because of the higher backhaul capacity requirements of 5G networks.
Key partner for aerospace prime
Filtronic’s principal products for the aerospace and defence market are highly integrated transmit and receive modules for airborne active electronically scanned array radars. It also offers switched filter banks for radar applications and microwave subsystems used in missile electronics. These applications require complex RF sub-systems to be packed within the limited space of a fighter jet airframe or missile. Filtronic’s expertise in hybrid design and assembly is ideal for these applications as it enables the company to provide uniquely small and thermally efficient modules and subsystems for harsh environments and those where weight reduction is critical. The company has been supplying its lead defence and aerospace customer, which is an aerospace prime, with highly integrated transmit and receive modules for airborne applications for more than ten years. It continues to work for this customer on multi-year contracts delivering transmit and receive modules for a range of aircraft platforms. These long-term delivery contracts provide a consistent level of demand for its manufacturing facilities and are supported by a manufacturing execution system, an enterprise resource planning system and a quality management system, which ensure that each component is both fully traceable and matched to the desired performance of the radar system. Filtronic has also worked on several contracts using its RF design expertise in the development and prototyping of next-generation radar systems. Business cycles are long in this sector, involving up to several years of collaborative development with the end client before volume manufacturing commences. However, once in the field, these programmes normally enjoy many years of continuing supply and support revenues. Since there are a limited number of UK-based suppliers with the necessary defence experience, Filtronic is a key partner for the aerospace prime.
Exhibit 3: Transmit and receive module for active electronically scanned array radar
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Extending the customer base
Until recently the defence market has been of limited interest to Filtronic because the equipment typically operated at low RF frequencies, providing limited opportunity for differentiation. As defence equipment spending has shifted to higher-frequency and more technically advanced radar and communications products, Filtronic’s manufacturing know-how and technical capabilities have become increasing applicable, enabling it to expand its customer base. In January 2021, Filtronic announced that it had won a contract worth £1.3m from the Defence Science and Technology Lab (DSTL, an executive agency of the UK’s Ministry of Defence) for the supply of battlefield radio communications hardware over a 12-month period. This was a new application area at the time. Filtronic successfully delivered prototype product and a limited production run relating to this contract in FY22. DSTL placed another order in July 2022 worth £0.5m for completion in FY23, to design, manufacture and deliver a modular, programmable reference system for testing RF equipment. The new test system will be compatible with land, sea and airborne platforms, enabling it to be used for both outdoor field trials and static laboratory-based testing. Filtronic has been invited to bid on other similar UK defence programmes with UK defence primes that require innovative multi-frequency RF solutions. During FY22 the company gained Information Assurance for Small and Medium Enterprises (IASME) Governance Gold cyber security accreditation and the company continues to invest into the company’s cyber security systems to facilitate more UK defence contract wins.
Although the market for land and ship-based radars is relatively small in comparison to aerospace, it still requires significant numbers of filters, electronic hybrids and RF sub-systems and this, together with emerging electronic warfare applications deploying high-frequency RF technology, represents an attractive market development opportunity for Filtronic. The company won a small land-based contract that was delivered in FY23 and is actively working on other opportunities for land and maritime radars.
Filtronic has also won several small development contracts for filters for defence applications. While these are modest, they have the potential to lead to more substantial projects and give access to a wider customer base. In July 2022, Filtronic announced that one of these development contracts, which was from an existing aerospace and defence customer, has resulted in a £0.4m order to manufacture prototype switched filter bank products for delivery in FY23.
Filtronic also provides contract manufacturing services for aerospace and defence clients, making and testing precision components at scale to individual specifications.
Investment in defence increasing
Intensifying geopolitical tensions are expected to lead to increased defence spending over the coming years. For example, a report from McKinsey & Company published in December 2022 estimated that even if Russia had not heightened security concerns by invading Ukraine, European defence spending would have risen from €296bn in 2021 to €337bn in 2026 (ie a 14% increase). In its low scenario, which factors in the invasion’s impact on defence funding, expenditure increases by 53% over the same period to reach €453bn. In its high scenario, which assumes a stronger response, spending increases by 65% to €488bn. In November 2020 the UK government announced a £16.5bn increase in defence spending above its manifesto commitment over the next four years. Together with a pledge to increase defence spending by 0.5% above inflation for every year of the current parliament, this represented an overall cash increase of £24.1bn over four years compared to the prior year budget. Some of the expenditure is being invested in providing enhanced capability and interoperability based on advanced radar systems, using ever more sophisticated RF solutions. In March 2021, the Integrated Review of Security, Defence and Foreign Policy included the commitment to an upgrade of the UK fleet of Typhoon radar systems and the development of the next-generation fast jet platform.
Critical communications market
An essential part of emergency services networks
The emergency services, federal agencies, defence bodies and some private security companies use communications infrastructure that is separate from commercial telecommunications networks. These networks need to be highly reliable even in harsh environments, available even in regions where there is no fibre network and secure. Historically Filtronic has focused on the North American critical communications market, which deploys the P25 network standard and where the market dynamics and the demand for higher resilience and longer-range communication have allowed the company to develop differentiated products.
Initially Filtronic supplied high-performance ceramic filters and combiners and RF conditioning products to this market, building a strong relationship with the leading OEM in this sector. In 2020 this lead customer, which we have previously inferred is Motorola Solutions, asked Filtronic to develop a new TTA ‘as fast as you can’ because the new specification had been released more than 12 months previously. The total development cycle took less than six months, from inception through to product qualification. The newly developed TTA met the updated specification and included performance improvements such as smart redundancy. The system continuously monitors the health of its amplifiers. If one of the amplifiers fails, the system can continue to operate using the spare amplifier. If both amplifiers are lost, the system will function in a bypass mode. The units are compact (229mm × 173mm × 51mm) and light (weighing less than 3.6kg), which reduces tower loading, and are designed to withstand lightning strikes. Filtronic’s systems are among a limited number on the market that are fully compliant with stringent US public safety specifications. The client was also interested in inventory reduction and increasing the speed of deployment with a target of reducing lead time from four weeks. Filtronic responded to this request by developing a modular architecture and simplifying the order process. It delivered its first TTA products for its customer to integrate into networks for its customers in May 2021. The customer has declared these TTAs to be ‘best-in-class’ and the product is being used for P25 programmes that will be implemented in the next 24 months. These TTA products are designed to be OEM agnostic, which has enabled Filtronic to make sales to other organisations outside of its lead customer.
Exhibit 4: Tower top amplifier
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Exhibit 5: Customised combiner
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Exhibit 4: Tower top amplifier
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Exhibit 5: Customised combiner
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Sustained investment in public safety supports long-term growth
Public safety networks typically receive good levels of investment at both city and state level as emergency services look to expand coverage, integrate services and replace legacy analogue networks. In January 2023 The Business Research Company predicted that the global mission-critical communication market size would grow from US$16.38bn in 2022 to US$18.10bn in 2023 and then to US$26.06bn in 2027 (ie at a CAGR of 9.5%). The report cites the rise in security threats related to cyberattacks as a key growth driver.
Historically these networks only supplied high-quality, high-reliability voice communication, so they tend to operate at narrowband microwave frequencies (700–900MHz). However, the communications equipment is evolving to support the speed and data requirements of new technologies used by the emergency services such as body-worn cameras. The market is therefore transitioning to hybrid solutions in which the mission-critical voice communications continue to run over dedicated and secure private communication networks, while non-critical data communications are carried over commercial-grade mobile telecommunication LTE networks. We note that the length of time required for accreditation, approval and adoption in this market is longer than in the commercial telecommunications market, however the length of time between product upgrades is longer too.
Benefiting from on-shoring
In FY20 Filtronic took the decision to transfer the manufacturing of P25 critical communication network products from a Chinese sub-contractor to its own facility in Maryland, US. The move was primarily designed to improve lead time and customer response times. It has had the additional benefit of positioning the company to benefit from ‘America First’ procurement policies.
Applying expertise of ultra-reliable networks to other sectors
Filtronic is applying its experience of delivering equipment for ultra-reliable, low latency and/or high-bandwidth public safety networks to other dedicated networks for specific industries. These include rail transportation, banking, utilities, manufacturing and the oil & gas industry. As discussed below, Filtronic is beginning to provide subsystems for some of these sectors.
Exhibit 6: Location of LEO satellites and HAPS
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Exhibit 7: Cerus power amplifier for high-capacity point-to-point satellite and HAPS applications
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Exhibit 6: Location of LEO satellites and HAPS
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Exhibit 7: Cerus power amplifier for high-capacity point-to-point satellite and HAPS applications
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New satellite constellations represent a significant opportunity
Constellations of hundreds of small, interconnected satellites are increasingly being deployed to provide internet connectivity to remote and rural areas where it is impractical and uneconomic to install fibre-optic links. Satellite constellations are also being used to provide environmental monitoring services and asset tracking and are being deployed by governments for Earth observation. Historically, most satellites were deployed in geostationary (GEO) orbits 36,000km above the Earth’s surface, with only a few complex, large and expensive satellites in fixed positions required to provide global coverage. Since GEO satellites are so far from the Earth, it takes a radio or light signal around 540 milliseconds to make the round trip from the ground to the satellite and back again. While this is acceptable for TV broadcasting, it is not suitable for internet communications, particularly online gaming, stock trading and other real-time applications. It also means that communication via GEO satellites is too slow for controlling driverless vehicles or tracking hypersonic missiles.
Consequently, the newer constellations designed to provide internet access deploy satellites in low Earth orbits, which are only 1,200km from the Earth’s surface. This architecture requires many more satellites to give global coverage. For example, as of end May Elon Musk’s Starlink constellation had nearly 4,200 LEO satellites in orbit. SpaceX, the owner of the Starlink constellation, has approval from the Federal Communications Commission to expand this to nearly 12,000 LEO satellites. OneWeb currently has 648 LEO satellites in orbit, which the company states is sufficient to achieve global coverage. Amazon has also announced its own satellite internet constellation called Project Kuiper, with a target of 3,236 LEO satellites. Under the terms of its FCC licence, it needs to have at least half of the constellation deployed and operating by July 2026 and it is preparing to launch two prototype satellites imminently.
Since there are so many satellites in these constellations, the traditional space industry procurement model of building customised equipment for individual satellites has had to be replaced by a more conventional commercial procurement model requiring suppliers to be able to deliver many hundreds of units in a timely and cost-effective manner. This shift represents a significant opportunity for Filtronic because it has both the RF design skills and volume manufacturing capability.
Some constellations, for example Starlink but not OneWeb, have communications links between the satellites themselves as well as to the Earth and back. Having inter-satellite links means that if a satellite receives a signal while it is above a region where there are no ground stations, or only ground stations owned by a hostile entity, it can transmit the signal back to Earth via a chain of inter-connected satellites. The shift to inter-satellite links creates additional opportunity for Filtronic.
Other platforms collectively referred to as high-altitude platform stations (HAPS) have been proposed as alternatives to LEO satellites. Google’s Loon project, which was started in 2011, was intended to provide internet access to people in rural and remote areas using a network of high-altitude communications balloons. The technology worked and was used to provide emergency communications to around 100,000 people in Puerto Rico following the devastation caused by Hurricane Maria in 2017. However, the project was not viable from an economic perspective. Users could lose connections if winds blew balloons off course. The solar-powered equipment on-board restricted the regions where the technology could be deployed. Crucially, the balloons cost tens of thousands of dollars each and needed to be replaced every five months as their plastic shells degraded, while there were few people in rural communities in the developing world able to pay for internet access. Google shut down Loon in 2021, stating that it was not a ‘long-term, sustainable business’. Facebook intended to construct a commercial airborne network based on its proprietary Aquila high-altitude solar power glider. This project was shelved in 2018, after two test flights, with Facebook announcing that it was continuing to work on a HAPS-based network, but with partners such as Airbus, which has developed its own Zephyr platform. In 2021 Airbus and NTT DOCOMO used a Zephyr to carry out tests that demonstrated the viability of stratospheric communications to devices such as smartphones. In 2022 Airbus signed a strategic partnership agreement with a Saudi telecommunications company to progress the development of HAPS-based connectivity and Earth observation services for the Kingdom of Saudi Arabia and a letter of intent with Space Compass for a cooperation agreement to service the Japanese market with mobile connectivity and Earth observation services.
mmWave transmission is a good option for links between a satellite, unmanned aerial vehicle or aircraft and the ground even though mmWave links do not deliver as high a data rate as free-space laser communications links. This is because mmWave technology is completely proven and transmission in certain frequencies, including E-band, is not seriously affected by rain or water vapour.
Dedicated offer for space applications
Since Filtronic has been supplying compact, highly integrated, reliable and cost-effective E-band backhaul telecommunications products in volume for over a decade, Filtronic was a natural choice for HAPS pioneers. The company worked on two important development programmes with large West-Coast US technology companies. While both programmes were eventually shelved, the work showed that Filtronic’s technology for horizontal line-of-sight links could be applied to vertical line-of-sight links over extended distances as well, and that Filtronic was able to meet the aggressive development time scales required. The HAPS-related development work was the foundation of Filtronic’s Cerus product line, which is dedicated to space-applications including deployment on LEO satellites. Cerus modules are based on Filtronic’s proprietary MMIC chips and are provided in a small form factor in a range of power outputs at E-band frequencies. The company is working on demonstration products at Ka, Q and V band frequencies for this sector.
In January 2023 Filtronic announced it had secured a contract with a new customer, which is a global provider of LEO satellite communications equipment. The contract is worth more than £2.0m, with revenue recognition expected in CY23. Filtronic will be delivering a customised version of its Cerus SSPA module for the contract. The customised modules and associated control boards will be installed in selected ground stations for commercial trials of the Eband Earth station antenna links to and from the LEO satellite. This will be the first time that high-bandwidth E-band frequencies have been used in an operational LEO application. In July, the company announced a contract with the European Space Agency worth €3.7m/£3.2m. This is focused on the development of multifrequency transceiver technology for satellite payload feeder links.
Filtronic continues to develop opportunities in adjacent markets where it can leverage its existing technology and capability, particularly applications in the licenced Q, V, E, W and D-bands. Filtronic’s Morpheus modules are a good basis from which to develop systems for other applications because they have a footprint of 90mm × 80mm and weigh only 110g. Emerging application areas include:
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Low-latency private networks: E-band links that meet 5G capacity requirements offer the user lower latency than that of a fibre cable of the same length. This makes private point-to-point mmWave links a more attractive solution for latency-critical applications such as automated, high-frequency financial trading systems, where reduced transaction times create a competitive advantage when trading shares. Filtronic has designed and supplied highly customised versions of its Orpheus and Morpheus E-band links to customers servicing the financial services market. These links have a significant advantage with respect to power consumption because they use Filtronic’s own MMICs. In December 2020 Filtronic secured a £0.4m development contract for a low-latency private network. In March this year this was followed by a contract worth US$0.8m (£0.6m) with a different customer for the design, development and manufacture of high-performance power amplifier modules, which will be incorporated into next-generation point-to-point microwave radios. The customer operates high-performance microwave and mmWave private networks. Management expects the revenue attributable to this contract will be recognised in FY24. Post year-end, the company announced it had won a further two contracts, each worth £0.5m, for delivery in CY24. Other applications where low-latency high-capacity networks could deliver significant advantages are plant safety control systems, security monitoring and autonomous vehicle controls.
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5G test equipment: the increased use of components operating at frequencies up to 55GHz presents challenges for test equipment manufacturers and creates an opportunity for Filtronic to design and manufacture modules operating at these higher frequencies for incorporation in automatic test equipment. In February 2020, the company received a US$1.0m contract to develop over-the-air 5G mmWave modules for a leading RF test equipment company in the United States. These modules extended the frequency range of the customer's existing product offering above 50GHz. The development contract was followed in October 2021 by a contract valued at US$0.8m (c £0.6m) to make pilot phase production units. In June 2022 Filtronic received a follow-on contract for full production units valued at US$0.9m (c £0.7m) for delivery during FY23.
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Quantum computing: recent developments in quantum computing require integrated switch filter banks that are able to operate both at room temperature and in cryogenic chambers where they have to withstand very low temperatures for extended periods. In July 2022, Filtronic announced the award of a contract from a quantum computing company for the design, development and supply of microwave filters and diplexers. They will be used within the microwave circuits of both the external control rack and the cryogenic dilution refrigerator of a quantum computer. Management expects that the contract, worth £0.35m, will be completed during FY23 and believes that it could lead to further work.