This paper describes the development and deployment of "tile" array technology, which is the foundation of lighter and cheaper AESA antennas. Close agreement is demonstrated between the modelled and measured performance of an X-band array, which provided azimuth and elevation beam-steering over a 20% bandwidth. Furthermore the authors show how the thinness of the tile can be exploited in a multi-facet antenna, and present the measured beam patterns of an experimental dihedral antenna.