Radomes protecting sensitive radar, navigational, and communications equipment of, e.g., aircraft, are strongly exposed to the environment and have to withstand harsh weather conditions and potential impacts. Besides their significance to the structural integrity of the radomes, it is often crucial to optimize the composite structures for best possible radio performance. Hence, there exists a significant interest in non-destructive testing techniques, which can be used for defect inspection of radomes in field use as well as for quality inspection during the manufacturing process. Contactless millimeter-wave and terahertz imaging techniques provide millimeter resolution and have the potential to address both application scenarios. We report on our development of a three-dimensional (3D) terahertz imaging system for radome inspection during industrial manufacturing processes. The system was designed for operation within a machining center for radome manufacturing. It simultaneously gathers terahertz depth information in adjacent frequency ranges, from 70 to 110 GHz and from 110 to 170 GHz by combining two frequency modulated continuous-wave terahertz sensing units into a single measurement device. Results from spiraliform image acquisition of a radome test sample demonstrate the successful integration of the measurement system.

We present thickness measurements with millimeter and terahertz waves using frequency-modulated continuous-wave (FMCW) sensors. In contrast to terahertz time-domain spectroscopy (TDS), our FMCW systems provide a higher penetration depth and measurement rates of several kilohertz at frequency modulation bandwidths of up to 175 GHz. In order to resolve thicknesses below the Rayleigh resolution limit given by the modulation bandwidth, we employed a model-based signal processing technique. Within this contribution, we analyzed the influence of multiple reflections adapting a modified transfer matrix method. Based on a brute force optimization, we processed the models and compared them with the measured signal in parallel on a graphics processing unit, which allows fast calculations in less than 1 s. TDS measurements were used for the validation of our results on industrial samples. Finally, we present results obtained with reduced frequency modulation bandwidths, opening the window to future miniaturization based on monolithic microwave integrated circuit (MMIC) radar units.

We present a rotational terahertz imaging system for inline nondestructive testing (NDT) of press sleeves for the paper industry during fabrication. Press sleeves often consist of polyurethane (PU) which is deposited by rotational molding on metal barrels and its outer surface mechanically processed in several milling steps afterwards. Due to a stabilizing polyester fiber mesh inlay, small defects can form on the sleeve’s backside already during the initial molding, however, they cannot be visually inspected until the whole production processes is completed. We have developed a fast-scanning frequenc-modulated continuous wave (FMCW) terahertz imaging system, which can be integrated into the manufacturing process to yield high resolution images of the press sleeves and therefore can help to visualize hidden structural defects at an early stage of fabrication. This can save valuable time and resources during the production process. Our terahertz system can record images at 0.3 and 0.5 THz and we achieve data acquisition rates of at least 20 kHz, exploiting the fast rotational speed of the barrels during production to yield sub-millimeter image resolution. The potential of automated defect recognition by a simple machine learning approach for anomaly detection is also demonstrated and discussed.

A novel photonic terahertz measurement system based on a frequency‐modulated continuous‐wave (FMCW) radar approach is presented. In previous works, fast frequency modulation has been demonstrated in connection with a continuous wave terahertz spectroscopy setup based on the photomixing principle. In this paper, a terahertz radar based on both a photomixing transmitter and a photomixing receiver, in contrast to the rigid spectroscopy approach, is reported. Hereby, frequency modulation bandwidths of more than 1.65 THz in radar operation is achieved. This corresponds to an order of magnitude more than what is previously achieved by terahertz radar systems. At the same time, measurement rates can be achieved that are comparable with radar systems based on Monolithic Microwave Integrated Circuits (MMICs) according to the current state of the art. Within the scope of the work, two operating modes are realized, one with a measurement rate of about 560 Hz at 600 GHz modulation bandwidth and one with 200 Hz at 1.65 THz modulation bandwidth, which can be set within the spectrum from 50 GHz to about 4.5 THz. The possibility to adjust the operating range of the radar without necessary hardware adaptations is another unique feature of the presented system, which allows the operator to choose a suitable frequency band that corresponds best to a certain measurement scheme via software settings. Besides the potential for multi‐layer thickness inspections, the capabilities of this technique for terahertz imaging applications are presented.

Terahertz tomography allows for non-contact tomographic inspection of dielectric materials without the need for radiation protection measures. Terahertz tomography offers the opportunity to inspect such objects from multiple angles not only by measuring the absorption but also by acquiring the time-of-flight of the radiation. Hence, this technique facilitates the reconstruction of the complete complex refractive index of a sample under test. Even complicated surface structures can be imaged, provided the feature size is above the diffraction limit roughly given by the wavelength of the terahertz radiation in use. For industrial applications, computational efficiency and imaging performance are crucial. Therefore, we apply the iterative conjugate gradient least square (CGLS) algorithm to reconstruct images from terahertz tomography data. To ensure reliable convergence of this semi-convergent CGLS algorithm a stopping mechanism based on the L-curve criterion is implemented. The result is a fast-converging, parallelizable method, which offers the flexibility to adapt to the specifics of terahertz tomography. As an example of this adaptability, we implement a non-negativity constraint, suppressing noise in the image and significantly enhancing reconstruction quality.

The field of terahertz and millimeter wave science and technology has evolved in recent years into an area attracting a lot of attention from all sides of science, industry, and the public