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Notre Dame Researchers Develop 3D Printed Ultra-Power-Efficient 5G Antenna

April 10, 2025

Researchers at the University of Notre Dame are developing a new low-power antenna for 5G networks using 3D printed artificial dielectric material. The technology aims to deliver 5G performance while using less than 10% of the energy consumed by current systems. The project is led by Jonathan Chisum, associate professor in the Department of Electrical Engineering, and is funded by the U.S. Army.

Notre Dame Researchers Develop 3D Printed Ultra-Power-Efficient 5G Antenna
Each antenna utilizes a 3D printed dielectric material with a repeating pattern of gyroid cells. (Image Credit: Angelic Rose Hubert.)

Current 5G networks consume significant power, with each base station using as much energy as 73 U.S. households. Chisum’s team has developed a millimeter-wave gradient index (GRIN) lens antenna that operates across all 5G frequency bands through a single device. This approach replaces multiple antennas and power-hungry chips with one system that leverages the physics of materials.

“Right now, a large portion of the cost to operate a cellular network is for electricity. If you look at a cell tower, you can see why: It uses a different antenna for each band, and these rely on active, powered chips,” Chisum said. “Our initial idea was simple: What if we could design similar capabilities into just one very wideband antenna by letting the physics of materials do the work normally done by many power-hungry chips.”

Each antenna prototype is constructed layer-by-layer through a detailed, 100-hour process. (Image Credit: Angelic Rose Hubert.)

The technology has applications for both military and civilian use. For the U.S. Army, the antenna’s wideband capabilities allow for operation across various global 5G frequencies while its low power consumption makes it suitable for mobile platforms. In the civilian sector, the technology could address cost barriers that have slowed the deployment of 5G millimeter-wave base stations.

The Notre Dame team is working to develop an efficient manufacturing process using 3D printing technology. Industry partners in the project include Cheshir Industries, a company co-founded by Chisum and Notre Dame doctoral graduates, and 3D Fortify, which specializes in RF design and manufacturing.

Source: news.nd.edu

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