An efficient design procedure based on modal‐matching method for axially corrugated dielectric‐rod‐loaded horns of complicated geometries is proposed in this paper. Calculation of the generalized scattering matrix of individual module, which is obtained by dividing the complex horn into simple sections, is carried out. Analytic expressions of power‐coupling integrals between different kinds of waveguides are presented, including those derived initially, which greatly shorten the calculation time. Techniques including the field equivalence principle and the spherical mode expansion are further implemented for radiation pattern prediction. A rexolite‐loaded axially corrugated horn antenna is finally investigated as a numerical experiment, with the frequency range of 17–33 GHz. The results obtained by our method and by commercial full‐wave simulation software are in excellent agreement, but our method is more efficient.