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Abstract The demand for lightweight antennas in 5 G/6 G communication, wearables, and aerospace applications is rapidly growing. However, standard manufacturing techniques are limited in structural complexity and easy integration of multiple material classes. Here we introduce charge programmed multi-material additive manufacturing platform, offering unparalleled flexibility in antenna design and the capability for rapid printing of intricate antenna structures that are unprecedented or necessitate a series of fabrication routes. Demonstrating its potential, we present a transmitarray antenna composed of an interconnected, multi-layered array of dielectric/conductive S-ring unit cells, reducing 94% mass of conventional antenna configurations. A fully printed circular polarized transmitarray system fed by a source and a Risley prism antenna system operating at 19 GHz both show close alignment between testing results and numerical simulations. This printing method establishes a universal platform, propelling discovery of new antenna designs and enabling data-driven design and optimizations where rapid production of antenna designs is crucial. 

Abstract Charge‐programmed 3D printing enables the fabrication of 3D electronics with lightweight and high precision via selective patterning of metals. This selective metal deposition is catalyzed by Pd nanoparticles that are specifically immobilized onto the charged surface and promises to fabricate a myriad of complex electronic devices with self‐sensing, actuation, and structural elements assembled in a designed 3D layout. However, the achievable property space and the material‐performance correlation of the charge‐programmed printing remain unexplored. Herein, a series of photo‐curable resins are designed for unveiling how the charge and crosslink densities synergistically impact the nanocatalyst‐guided selective deposition in catalytic efficiency and properties of the 3D printed charge‐programmed architectures, leading to high‐quality 3D patterning of solid and liquid metals. The findings offer a wide tunability of the structural properties of the printed electronics, ranging from stiff to extreme flexibility. Capitalizing on these results, the printing and successful application of an ultralight‐weight and deployable 3D multi‐layer antenna system operating at an ultrahigh‐frequency of 19 GHz are demonstrated. 

Abstract Designing and printing metamaterials with customizable architectures enables the realization of unprecedented mechanical behaviors that transcend those of their constituent materials. These behaviors are recorded in the form of response curves, with stress-strain curves describing their quasi-static footprint. However, existing inverse design approaches are yet matured to capture the full desired behaviors due to challenges stemmed from multiple design objectives, nonlinear behavior, and process-dependent manufacturing errors. Here, we report a rapid inverse design methodology, leveraging generative machine learning and desktop additive manufacturing, which enables the creation of nearly all possible uniaxial compressive stress‒strain curve cases while accounting for process-dependent errors from printing. Results show that mechanical behavior with full tailorability can be achieved with nearly 90% fidelity between target and experimentally measured results. Our approach represents a starting point to inverse design materials that meet prescribed yet complex behaviors and potentially bypasses iterative design-manufacturing cycles. 

Architected metamaterials have emerged as a central topic in materials science and mechanics, thanks to the rapid development of additive manufacturing techniques, which have enabled artificial materials with outstanding mechanical properties. This Letter seeks to investigate the elastodynamic behavior of octet truss lattices as an important type of architected metamaterials for high effective strength and vibration shielding. We design, fabricate, and experimentally characterize three types of octet truss structures, including two homogenous structures with either thin or thick struts and one hybrid structure with alternating strut thickness. High elastic wave transmission rate is observed for the lattice with thick struts, while strong vibration mitigation is captured from the homogenous octet truss structure with thin struts as well as the hybrid octet truss lattice, though the underlying mechanisms for attenuation are fundamentally different (viscoelasticity induced dampening vs bandgaps). Compressional tests are also conducted to evaluate the effective stiffness of the three lattices. This study could open an avenue toward multifunctional architected metamaterials for vibration shielding with high mechanical strength. 

Printed low-density materials form microrobots capable of high-speed motion, force output, and self-sensing feedback.