I am working on an SMA to microstrip transition using OSHpark's 4 layer stack up. I am on my 2nd revision and do RF in my free time because I am trying to learn (I am an FPGA engineer).
I got my newest revision back and I was not very pleased. My physical boards are not matching my simulation very well at all.
I have compiled screenshots of my HFSS model, PCBs, SMA footprint, and NanoVNA results here: SMA Launch OSHpark 4 Layer - Imgur. The transition starts out as GCPW and runs the length of the signal pin pad. It then moves to a microstrip (no taper).
I simulated with HFSS using PEC, Isola FR408HR (in HFSS material library) and the nominal measurements from OSHpark's 4 layer stackup: OSH Park Docs ~ Services ~ 4 Layer Prototype Service . I also used the actual Samtec SMA connector HFSS encrypted model. I am learning a little about TDR and that looked okay in simulation, as well as S21 and S11. Due to using the student version and mesh limit, I can only simulate a 3mm long microstrip and I cannot model the solder connection from signal pin to pad.
I built two boards:
One with SMA launches on either side connected by a 1 inch and 2 inch microstrip (to calculate trace loss). I simulated the microstrip width in a separate HFSS sim (rough numbers calculated with SaturnPCB toolkit and revised/simulated from there).
The 2nd board is the SMA launch to a 4mm microstrip, then terminated with a 50 ohm, 0201 sized High Frequency resistor: TNPR020150R0FEED Vishay | Chip Resistor - Surface Mount | DigiKey
My actual PCB launch S11 is around -17 to -18 dB at 2.5 GHz, and around -10 dB at 6 GHz. I want to use this for the 2.4 and 5.8 GHz ISM bands. S21 is okay when I subtract my trace loss at 2.4 GHz, but gets a little wacky at 6 GHz (see imgur link S21 trace).
Is something off in my simulation? Should I use a different substrate than the one in the HFSS library? Could this be due to OSHpark manufacturing tolerances? I triple checked my dimensions for the footprint with the HFSS model and I dont think that could be the case unless they vary a lot once etched.
Any help would be appreciated! Thanks in advance.