Future Deep Space (DS) ground stations envisioned by running projects funded by major space agencies are based on arrays of reflector antennas operating in different frequency bands. Therefore, a multi-band feeding system is required for each antenna, and a possible solution foresees the use of dichroic mirrors to separate/combine different beams. This paper presents a low-cost and fast manufacturing process for the fabrication of dichroic mirrors, usually referred to as punching technique or metal stamping. In particular, the specific advantages and limits of this fabrication technique are outlined and discussed, showing both electrical performance and manufacturing accuracy measurements from a test prototype. In addition, a typical scenario for future DS ground stations is described, showing the impact of these low-cost dichroic mirrors on the final ground station performance and cost, compared to the standard approach for dichroic mirror manufacturing based on more expensive and time-consuming technologies (e.g. milling machining).
