The demand for light and high performance antennas in peak fields such as 5G / 6G communications, portable devices and aerospace continues to grow. However, traditional manufacturing processes have important limits in complex geometric design and multi-material integration. According to the resource database, the first article in 3D printing in 2025, “Nature Communications” proposed a sort ofPlatform for manufacturing multi-material programming multi-material additivesCan achieve the impression of an ultra-light antenna structure.
A research team led by Professor Associate UC Berkeley Zheng Xiaoyu has developed this innovative 3D printing platform that considerably simplifies the process of producing complex antenna structures. The platform is named“Programmed load, CPD” (programmed load deposit, CPD)Its basic technology is to effectively combine highly conductive metals with various dielectric materials in a three -dimensional structure.
Unlike traditional methods that require the use of costly metallic powders and high energy lasers, the CPD platform uses 3D printing technology based on light hardening. The combination of catalytic materials allows a directional metal deposit on the polymer matrix, thus successfully producing complex structures, light and excellent antennas.
1. Research context
With the rapid development of 5G / 6G communication, the Internet of Things (IoT) and small satellite communications, the demand for light and high performance antennas increases. However, traditional lithography and machining processes are difficult to meet the requirements of the new generation of antennas design due to the limits of complex geometric structures and the integration of multilayer materials.
Additive manufacturing technology (AM) has brought new opportunities to the manufacture of antennas, allowing certain 3D structural or multilayer conceptions. However, most existing processes can only use one material or require a complex and multi-processes collaboration to combine metals and dielectrics, resulting in bulky processes, a high cost of support materials and an increase in overall weight.
2. Research methods
The research team used projection stereolithography technology (SLA) to form a three -dimensional structure by mixing photomonomers with different polar groups in the printing resin. Inside the printing, specific areas carry loads while others remain neutral. Subsequently, metallic inks (such as copper ions precursors) are deposited selectively in loaded areas, while homogeneous polar or neutral areas are not deposited. Thanks to this process, precise control of the metal deposit positions can be obtained at the microscopic scale.
Among them, the metal part adopts an autocatalytic process to integrate nanoparticles of palladium metal in the surface of the loaded region, providing a substrate for the controllable deposit of highly conductive metals such as copper, and ultimately uniform growth of highly conductive metals.
The dielectric part adds different loads (such as low dielectric loss resin, ceramic powder or elastomer) to resin to meet design needs, thus adjusting dielectric constant and mechanical properties, so that the antenna has multifunctional characteristics.
Finally, in order to reach greater industrial quality antennas, the researchers adopted a modular splicing design and connected various components via Snap-On interfaces, which improves not only structural integrity, but also obtains a practical assembly and replacement.
The key manufacturing process includes the following steps: First print a 3D substrate with a motif load via SLA technology; Then immerse the print part in the veneer tank, and selectively deposit the functional immersion and healing process is repeated for the construction of the multiplied metal shape and the structure challenging at the multi-bassing height; NA manufacturing with ultra-lighter properties.
3. Research results
1. antenna of the ultra-light transmission panel
The research team has demonstrated a network antenna transmitting to 19 GHz based on CPD technology, made up of three layers of dielectric components / interconnected conductors. The overall weight of this antenna is only 1/10 of that of a traditional PCB antenna (weight loss at 94%). The test results show that its characteristics of transmission and phase compensation coefficient at 19 GHz are very consistent with digital simulation and maintain stable electromagnetic performance over a wide angular range.
2. Large opening antenna
Thanks to modular splicing technology, the researchers divided the antenna into four modules and printed them in emission networks with diameters of 12 cm and 20 cm. The tests show that the performances of the spilled antenna are fundamentally the same as those of the primary training antenna, with only slight differences of less than 0.2 dB in the directionality and the width of the beam.
3. Structure of the horned antenna and wave guide
The research team has extended CPD technology to COR antennas and has designed light antennas with complex internal channels. The transition structure of the diaphragm polarizer and the serpentine wave guide is significantly reduced by internal integration into the diaphragm polarizer and the serpentine wave guide and coated with a layer of ultra-thin copper on the key surface. At the same time, its performance model of radiation and axis ratio are very consistent with the simulation value.
4. Warm control and multifunction integration
After having optimized the design, the research team combined the transmission network and the horn antenna in a complete 3D printed antenna system, demonstrating the Risley Prism (RPA) antenna function of the 2D beam scan, checking the potential of this technology in high integration and a systematic design.
4. Summary of perspectives
Research shows that the performance of the process antenna in the 19 GHz band is very consistent with digital simulations, showing potential in microwave, millimeter and higher frequency waves (like Terahertz). By introducing special loads or adjusting the thickness of the metal layer, losses can be further reduced and gains can be improved. However, the current process is low in automation, requiring manual replacement and cleaning of materials, and performance at extreme temperatures and high frequencies still require additional verification. The research team stressed that by optimizing the material and improving the uniformity of the metal layer, the ohmic losses can be considerably reduced.
To summarize, this manufacturing technology of multi-material load-material additives produces the design of light and high performance antennas, bringing new possibilities to 5G / 6G, satellite communications and portables. With an additional improvement in automation and materials systems, 3D loading programming printing should become an important technical route for mass production and rapid iteration of high -performance antennas in the future.
