Ultra-light antennas via charge programmed deposition additive manufacturing

Zhen Wang, Ryan Hensleigh, Zhenpeng Xu, Junbo Wang, James JuYoung Park, Anastasios Papathanasopoulos, Yahya Rahmat-Samii () and Xiaoyu Zheng ()
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Zhen Wang: University of California
Ryan Hensleigh: University of California
Zhenpeng Xu: University of California
Junbo Wang: University of California
James JuYoung Park: University of California
Anastasios Papathanasopoulos: University of California
Yahya Rahmat-Samii: University of California
Xiaoyu Zheng: University of California

Nature Communications, 2025, vol. 16, issue 1, 1-10

Abstract: Abstract The demand for lightweight antennas in 5 G/6 G communication, wearables, and aerospace applications is rapidly growing. However, standard manufacturing techniques are limited in structural complexity and easy integration of multiple material classes. Here we introduce charge programmed multi-material additive manufacturing platform, offering unparalleled flexibility in antenna design and the capability for rapid printing of intricate antenna structures that are unprecedented or necessitate a series of fabrication routes. Demonstrating its potential, we present a transmitarray antenna composed of an interconnected, multi-layered array of dielectric/conductive S-ring unit cells, reducing 94% mass of conventional antenna configurations. A fully printed circular polarized transmitarray system fed by a source and a Risley prism antenna system operating at 19 GHz both show close alignment between testing results and numerical simulations. This printing method establishes a universal platform, propelling discovery of new antenna designs and enabling data-driven design and optimizations where rapid production of antenna designs is crucial.

Date: 2025
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DOI: 10.1038/s41467-024-53513-w

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