Scientists at Washington State University have developed a new kind of flexible wireless system that could change how communication devices are made.
Their invention combines 3D-printed antenna arrays with a special chip-sized processor, creating technology that could be used in wearable devices, aircraft, cars, and even space equipment.
The work, published in Nature Communications, shows how 3D printing and new materials can make wireless systems smaller, lighter, and more adaptable.
Traditional antennas are rigid and can’t bend or flex without losing performance.
This limits their use in wearable electronics or moving structures such as airplane wings or drones.
The WSU-led team found a way around this by using 3D printing and a custom ink made of copper nanoparticles.
The copper ink, developed with researchers from the University of Maryland and Boeing, allows the antennas to keep working even when bent, exposed to humidity, or subjected to temperature and salt changes.
Copper is a good conductor of electricity, and the nanoparticle formulation helps maintain strong performance in flexible systems.
“The ink is a very important part of 3D printing,” explained Subhanshu Gupta, associate professor in WSU’s School of Electrical Engineering and Computer Science.
“The nanoparticle-based ink developed by our collaborators is powerful for high-end communication circuits like what we’re doing.”
To make the system even more reliable, the researchers also created a small processor chip that automatically corrects any distortions in the antenna’s signal.
When flexible antennas move or vibrate, their shape changes slightly, which can disrupt the signal. The processor continuously monitors and adjusts for these changes in real time.
“We used this processor to correct for material deformities and vibrations,” Gupta said. “Doing this in real time makes it very attractive for future applications.”
The team successfully built and tested a lightweight, flexible array of four antennas that could send and receive signals even when bent or in motion. The antennas use very little power and can be easily scaled up.
Because each antenna tile works independently, many tiles can be combined to form larger arrays. In their prototype, the researchers connected four arrays, creating a system with 16 antennas that worked together smoothly.
This new technology opens the door to many possibilities—from smart textiles that communicate wirelessly to aircraft covered in thin, flexible antenna layers.
The combination of 3D printing, copper nanoparticle ink, and real-time signal correction could make future wireless systems more efficient, adaptable, and affordable than ever before.
