Making a Satellite Dish
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Mixing
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Satellite dishes are comprised of many different materials. These materials include resin, various metals and calcium. They are mixed together to form a paste. The exact composition of the paste varies from manufacturer to manufacturer and is based on the requirements of the dish. Certain materials, for instance, will capture signal better than others, so those materials may be used with greater frequency in more sophisticated dishes.
Pouring
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The mixture of materials is poured onto a film of polyethylene. This film is prepared with a layer of chopped fiberglass.
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Heating
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The paste mixture is heated on the fiberglass and film to about 90 degrees Fahrenheit. This makes the mixture cook, or cure; the final product is a sheet with three layers that can be shaped into the familiar dish shape.
Shaping
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Once the paste has been heated and cured, high pressure is used to shape the dish. The shape of most modern dishes is a parabola due to the fact that this shape is better at capturing waves (signals) than others.
Trimming, Cooling and Painting
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The shaped dish is trimmed to size and allowed to cool. The size of the dish varies widely based on for whom it is manufactured. Some cable companies, for instance, have dishes several feet in diameter to catch all the signals from various networks easily. The average home satellite dish usually is only about 12 to 24 inches in diameter. The dish is painted once trimming and cooling are complete; after that it is ready for packing and shipment.
Aluminum Dishes
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Aluminum satellite dishes undergo a slightly different process than fiberglass dishes. Holes are drilled into a plate of aluminum, which is then heated up so it can be shaped and trimmed. The dish is then coated with paint powder and heated to melt and secure the paint to the dish.
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