Demand for lightweight, high-performance antennas continues to grow in cutting-edge areas such as 5G/6G communications, wearable devices and aerospace. However, traditional manufacturing processes have significant limitations in terms of designing complex geometric structures and multi-material integration. According to the resource library, the first Nature Communications article on 3D printing in 2025 proposed aLoad-programmed multi-material additive manufacturing platformcapable of printing ultra-light antenna structures.
A research team led by Zheng Xiaoyu, associate professor at UC Berkeley, developed this innovative 3D printing platform, which significantly simplifies the process of producing complex antenna structures. The platform is named“Charge-programmed multi-material 3D printing” (Charge-programmed deposition, CPD)its core technology involves efficiently combining highly conductive metals with various dielectric materials into a three-dimensional structure.
Unlike traditional methods that require the use of expensive metal powders and high-energy lasers, the CPD platform uses 3D printing technology based on photopolymerization. The combination of catalytic materials enables directional deposition of metals on polymer matrices, leading to the successful fabrication of complex, lightweight, high-performance antennas.
1. Research context
With the rapid development of 5G/6G communications, Internet of Things (IoT) and small satellite communications, the demand for lightweight and high-performance antennas continues to grow. However, traditional photolithography and machining processes are difficult to meet the requirements of next-generation antenna design due to the limitations of complex geometric structures and multilayer material integration.
Additive manufacturing (AM) technology offers new opportunities for antenna manufacturing and allows certain 3D structures or multi-layer designs to be produced. However, most existing processes can only use a single material or require complex multi-process collaboration to combine metals and dielectrics, resulting in tedious processes, high consumption of support materials, and increased overall weight. .
2. Research methods
The research team used projection stereolithography (SLA) technology to form a three-dimensional structure by mixing photomonomers with different polar groups in the printing resin. Within the print, specific areas are loaded, while other areas remain neutral. Subsequently, the metallic ink (such as the copper ion precursor) is selectively deposited in the charged areas by electrostatic adsorption, while no deposition occurs in the same polar or neutral areas. Through this process, precise control of the metal deposition position can be achieved on a microscopic scale.
Among them, the metal part uses an autocatalytic process to incorporate palladium metal nanoparticles on the surface of the charged area, thereby providing a substrate for the controlled deposition of highly conductive metals such as copper, and ultimately achieving growth. uniformity of highly conductive metals.
In the dielectric part, different fillers (such as low dielectric loss resin, ceramic powder or elastomer) are added to the resin to meet the design requirements, thereby adjusting the dielectric constant and mechanical properties to make the multifunctional antenna.
Finally, in order to achieve a larger industrial-grade antenna, the researchers adopted a modular splice design and connected various components via snap-on interfaces, which not only improved the structural integrity, but also enabled convenient assembly and replacement.
The key manufacturing process includes the following steps: firstly, printing a 3D substrate with patterned fillers via SLA technology; then the printed part is immersed in an electroplating tank and electrostatic adsorption is used to selectively deposit copper or other functional metals depending on; design requirements, repeat the impregnation and curing processes to gradually build a multi-layer metal-dielectric interpenetrating structure, and finally carry out post-curing and surface treatment to complete the manufacturing of high-performance antennas with ultra-light characteristics.
3. Search results
1. Ultra-light transmission array antenna
The research team demonstrated a 19 GHz transmitting array antenna based on CPD technology, consisting of three layers of interconnected S-ring dielectric/conductive elements. The total weight of the antenna is only 1/10 of traditional PCB antenna (94% weight reduction). Test results show that its transmission coefficient and phase compensation characteristics at 19 GHz are highly consistent with numerical simulations, and it maintains stable electromagnetic performance over a wide angle range.
2. Large aperture expandable antenna
The researchers used modular splicing technology to divide the antenna into four modules, print them, and assemble them into transmission arrays with diameters of 12 cm and 20 cm. Tests show that the performance of the spliced antenna is basically the same as that of the single molded antenna, with only slight differences of less than 0.2 dB in directivity and beamwidth.
3. Lightweight horn antenna and waveguide structure
The research team extended CPD technology to horn antennas and designed lightweight antennas with complex internal channels. Significant weight savings (weight reduction of more than 5 times) are achieved by internally integrating the diaphragm polarizer and the sinuous waveguide transition structure, and plating ultra-thin copper layers on the surfaces reviews. At the same time, its performance in terms of radiation pattern and axial ratio remains very consistent with the simulated values.
4. Beam steering and multifunctional integration
After further optimizing the design, the research team combined the transmission array and horn antenna into a fully 3D printed antenna system, demonstrating the function of the scanning Risley Prism Antenna (RPA). of 2D beam and verifying the potential of this technology in a highly integrated and systematic design.
4. Summary and perspectives
Research shows that the antenna performance of this process in the 19 GHz frequency band is very consistent with numerical simulation, showing potential in the microwave, millimeter wave, and higher frequency bands ( such as terahertz). By introducing special fillers or regulating the thickness of the metal layer, the loss can be further reduced and the gain increased. However, the current process has a low degree of automation, requiring manual replacement and cleaning of materials, while performance under extreme temperatures and frequencies still requires further verification. The research team noted that ohmic losses can be significantly reduced by optimizing materials and improving the uniformity of metal layers.
In summary, this programmed charge multi-material additive manufacturing technology enables lightweight, high-performance and complex antenna designs, opening new possibilities for areas such as 5G/6G, satellite communications and wearable devices. With the continuous improvement of automation and hardware systems, charge-programmed 3D printing is expected to become an important technical avenue for mass production and rapid iteration of high-performance antennas in the future.
