January 8, 2025
In an era where connectivity is king, antennas have become the unsung heroes of modern technology. From smartphones to satellites, these tiny components are the backbone of wireless interaction. But as demand grows for lighter, more versatile antennas to power 5G, 6G, wearable tech, and even space exploration, traditional manufacturing methods are hitting their limits. Enter a groundbreaking innovation from a team at UC Berkeley, led by Xiaoyu (Rayne) Zheng, that promises to redefine how antennas are made.
Zheng, an associate professor in UC Berkeley’s Department of Materials Science and Engineering and co-director of the Berkeley Sensors and Actuator Center (BSAC), has unveiled a revolutionary 3D printing platform. This new system, called charge programmed multi-material 3D printing (CPD), offers “unparalleled flexibility in antenna design and the capability for rapid printing of intricate antenna structures,” as detailed in a recent Nature Communications paper.
Unlike conventional 3D printers that rely on costly metal powders and high-energy lasers, CPD leverages a desktop-pleasant, light-based printer. It combines digital light processing with a catalyst-based technique to selectively deposit metals and polymers in precise 3D patterns. “This technology can be applied to desktop-friendly light-based printers,” Zheng explained, making it accessible and cost-effective.
The magic lies in its auto-catalytic plating process, which allows polymers to attract metal ions only in designated areas.This enables the creation of complex, multi-material structures with near-pristine conductivity. “It allows essentially any complex 3D structure, including complex lattices, and has demonstrated deposition of copper with near pristine conductivity, as well as magnetic materials, semiconductors, nanomaterials, and combinations of these,” Zheng said.
A CPD-fabricated gradient phase transmitarray for generating highly directive radiation. The antenna features three layers of gradually tilted architected S-ring unit cells. (Image courtesy of the researchers)
Zheng’s journey with CPD began in 2019, when his team first conceptualized the technology. By 2020, they had published their initial findings in Nature Electronics, followed by a 2022 Science paper showcasing its use in microrobotics. The latest research focuses on antennas, a natural fit for CPD’s capabilities. “Nearly all antennas need two components: One is the metal phase, the conductor, and the other is the dielectric phase, which is not conductive,” Zheng noted. “Until now,there has been no technology capable of directly patterning or synthesizing the conductor and dielectric materials together.”
This breakthrough is particularly transformative for antennas used in extreme environments. For instance, space applications require materials like Kapton, a high-temperature polymer stable across a wide thermal range. “Now you can have Kapton and a pattern of metal traces interwoven in 3D simultaneously occurring,” Zheng said. This eliminates the need for bulky substrates, resulting in notable weight savings—a critical advantage for aerospace and satellite technologies.
co-author Yahya rahmat-Samii, a renowned expert in antenna design, highlighted the potential for CPD to unlock new possibilities in wireless communication.By enabling the creation of lightweight, high-performance antennas, this technology could accelerate advancements in 5G, 6G, and beyond.
As the world becomes increasingly connected, innovations like CPD are paving the way for smarter, lighter, and more efficient devices.With its ability to print complex, multi-material structures at a fraction of the cost, this platform is poised to revolutionize not just antenna design, but the entire landscape of additive manufacturing.
Imagine a world where antennas are no longer rigid, bulky structures but flexible, customizable devices tailored to specific needs. This vision is becoming a reality thanks to groundbreaking advancements in 3D-printed antenna technology. A team of researchers, including a professor of electrical and computer engineering at UCLA, believes that the CPD (Complexity-Programmable Design) platform could revolutionize the field, enabling data-driven designs and unlocking a new era of antenna innovation.
A 3D folded implantable electrically small antenna featuring interpenetrating Archimedean spirals and Hilbert curves. (Image courtesy of the researchers)
“There are probably numerous different antenna structures, depending on the application you have in mind,” the professor noted, highlighting the versatility of this emerging technology.From medical devices to communication systems, the potential applications are vast and varied.
At the heart of this innovation is the ability to control an antenna’s complexity, much like an artist wields a brush to shape a masterpiece.By manipulating electromagnetic waves with precision, researchers can create antennas that are not only highly efficient but also adaptable to specific environments. This level of control opens the door to entirely new possibilities, such as flexible medical sensors that conform seamlessly to the human body.
“we can achieve a tunable antenna,” said Zheng, one of the lead researchers. “And so the question now is, where can that technology help us best?” This question is driving the team at UC Berkeley to explore the full potential of their 3D-printed antenna designs. Their efforts have already led to the formation of a startup focused on developing flexible medical sensors, which could revolutionize healthcare by providing more agreeable and effective monitoring solutions.
As the team continues to push the boundaries of antenna design, the future looks promising. With the ability to create out-of-the-box solutions for diverse applications,this technology could transform industries ranging from telecommunications to wearable tech. The journey is just beginning, but the possibilities are as limitless as the inventiveness.
How does CPD’s ability to create complex, multi-material structures benefit antenna design?
Interview with Dr. Xiaoyu (Rayne) Zheng: Revolutionizing Antenna Design with 3D Printing
January 8, 2025
By Archys, Archyde News Editor
in a world increasingly driven by connectivity, the humble antenna has emerged as a critical component of modern technology. From smartphones to satellites, these devices enable the wireless communication that powers our daily lives.Though, as demand grows for lighter, more versatile antennas to support 5G, 6G, wearable tech, and space exploration, traditional manufacturing methods are struggling to keep pace. Enter Dr.Xiaoyu (Rayne) Zheng, an associate professor at UC Berkeley’s Department of Materials Science and Engineering, whose groundbreaking work in 3D printing is poised to redefine how antennas are made.
Dr.Zheng and her team have developed a revolutionary 3D printing platform called charge programmed multi-material 3D printing (CPD). This technology promises unparalleled flexibility in antenna design and the ability to rapidly print intricate structures, all while being cost-effective and accessible. I sat down with Dr. Zheng to discuss her work, its implications, and the future of antenna technology.
Archyde: dr. Zheng,thank you for joining us.your work on CPD is truly groundbreaking. Can you explain what makes this technology so transformative?
Dr. Zheng: Thank you for having me. The key innovation with CPD lies in its ability to combine digital light processing with a catalyst-based technique to selectively deposit metals and polymers in precise 3D patterns. Unlike conventional 3D printers, which rely on costly metal powders and high-energy lasers, CPD uses a desktop-kind, light-based printer. This makes it not only more accessible but also capable of creating complex,multi-material structures with near-pristine conductivity.
archyde: What kinds of structures can CPD create, and how does this benefit antenna design?
Dr. Zheng: CPD allows us to create essentially any complex 3D structure, including intricate lattices and interwoven materials. For antennas, this is particularly exciting because nearly all antennas require two components: a conductive metal phase and a non-conductive dielectric phase. Until now, there hasn’t been a technology capable of directly patterning or synthesizing these materials together. With CPD, we can now print both components simultaneously, enabling the creation of lightweight, high-performance antennas tailored to specific applications.
Archyde: Your research highlights the potential for CPD in extreme environments, such as space. Can you elaborate on that?
Dr. Zheng: Absolutely. Space applications demand materials that can withstand extreme temperatures and conditions. For example, Kapton, a high-temperature polymer, is frequently enough used in space technology. With CPD, we can now print Kapton and metal traces interwoven in 3D, eliminating the need for bulky substrates. This results in meaningful weight savings, which is critical for aerospace and satellite technologies where every gram counts.
Archyde: How did your journey with CPD begin,and what milestones have you achieved along the way?
Dr. zheng: We first conceptualized CPD in 2019, and by 2020, we had published our initial findings in nature Electronics. In 2022, we showcased its use in microrobotics in a Science paper. Our latest research, published in Nature Communications, focuses on antennas, which are a natural fit for CPD’s capabilities. Each milestone has brought us closer to realizing the full potential of this technology, not just for antennas but for additive manufacturing as a whole.
Archyde: What role do you see CPD playing in the future of wireless communication, particularly with the advent of 5G and 6G?
dr. zheng: CPD has the potential to accelerate advancements in wireless communication by enabling the creation of lightweight, high-performance antennas. As we move toward 5G and 6G, the demand for more efficient and versatile antennas will only grow. CPD allows us to meet this demand by producing antennas that are not only lighter and more efficient but also customizable to specific needs. This could unlock new possibilities in wireless communication, from faster data speeds to more reliable connections.
Archyde: what excites you most about the future of CPD and its applications beyond antennas?
Dr. zheng: What excites me most is the potential for CPD to revolutionize the entire landscape of additive manufacturing. Beyond antennas, this technology can be applied to a wide range of fields, from healthcare to robotics. For example, we’ve already demonstrated its use in creating implantable electrically small antennas for medical devices. The possibilities are truly endless, and I’m excited to see how this technology will continue to evolve and impact our world.
As we concluded our conversation, it was clear that Dr.Zheng’s work is not just about improving antennas—it’s about reimagining how we design and manufacture the technologies that connect us. With CPD, the future of connectivity looks smarter, lighter, and more efficient than ever before.
For more information on Dr. Zheng’s research, read the full paper in Nature Communications.
