Structure and method for an aperture plate for use in a phased array antenna is disclosed. The aperture plate includes a plurality of waveguide transitions, each with a radiating end, a coupling end and a body portion extending from the radiating end to the coupling end. The waveguide transitions are spaced apart from each other wherein at least a pair of waveguide transitions are spaced apart closer to each other at the radiating end than at the coupling end. The method of manufacturing an aperture plate for a phased array antenna includes sizing a plurality of waveguide transitions based upon certain operating requirements, determining a radiating lattice spacing and configuration based upon the operating requirements, determining a coupling lattice spacing and configuration based upon antenna electronics packaging, optimizing an aperture plate thickness to achieve the radiating lattice and the coupling lattice spacing and configuration, and forming the aperture plate.