Abstract: While considering the engineering application requirements of the transmitter and receiver (T/R) modules of low-profile, high-power, multi-functional active phased radar systems within the Ku-band, the traditional brick-type T/R modules suffer from large structural dimensions and low-level integration, making it difficult to meet the design requirements of radar platforms while upgrading to lower profile, miniaturization, and conformal design. Therefore, a high-integration, high-power stacked T/R module within the Ku-band is developed in the paper. The design of the module overcomes multiple key technical challenges, including integrated hybrid high-density integration, high-precision three-dimensional stacked vertical interconnection, high-efficiency dissipation of heat with high heat flux density, complex electromagnetic compatibility in confined space, and gradient aluminum-silicon integrated packaging, and provides a feasible technical solution for achieving high-density integration, miniaturization, and lightweight design of T/R modules. In this paper, the methods of principle design, circuit design and high-precision vertical interconnection design of the T/R module are comprehensively elaborated; meanwhile, a robust optimization model for high-density integration and multi-field coupling design is proposed by introducing the idea of transfer function, effectively solving the stability issue of the T/R module in confined space and significantly improving the module′s design efficiency. Physical fabrication and testing of the module, based on the above design, are carried out. The results show that the module exhibits superior consistency in amplitude and phase performance, excellent manufacturability, and ease of engineering and mass production, and it has been successfully applied to equipment platforms such as novel chip-based multi-functional radar system.