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A new type of 3D-printed antenna could transform how vehicles, drones, and wearable devices maintain wireless communication while in motion. Developed by researchers at Washington State University (WSU) with partners from the University of Maryland and Boeing, the flexible antenna system is designed to keep signals stable even when bent, vibrated, or exposed to challenging environmental conditions.
Traditional flexible antennas often face reliability problems: when the surface they’re attached to moves or bends, their shape changes slightly, which causes drops or distortions in the wireless signal. This has long limited their use in settings such as aircraft wings, automotive panels, or wearable electronics, where movement is constant.
The WSU-led team tackled this issue using 3D printing and a copper nanoparticle-based ink that enhances electrical performance. The result is a lightweight array of four antennas that can be printed directly onto curved or flexible surfaces, effectively turning them into part of the communication system. Testing showed that these antennas maintain consistent performance under mechanical stress, humidity, temperature shifts, and exposure to salt, which are conditions that typically degrade electronic components.
According to Interesting Engineering, an additional innovation is the custom processor developed to work alongside the antenna array. This chip continuously monitors the signal and corrects any distortions caused by material movement or vibration. The correction happens in real time, ensuring that the wireless connection remains stable even when the surface flexes.
The antennas are modular, designed as small tiles that can be scaled up to form larger networks. In trials, researchers combined four tiles to create a 16-antenna array capable of sending and receiving signals efficiently while on the move. The low power consumption and adaptability make the design suitable for a range of applications, from unmanned aerial vehicles to satellites and smart textiles.
If commercialized, this approach could enable new generations of embedded communication systems—integrating antennas seamlessly into the structure of aircraft, vehicles, or even clothing—without compromising signal quality.
The findings were published in the Nature Communications Journal.
