Green Antennas for Blue Skies – Solving the sustainability and efficiency challenges

Mobile communication has evolved tremendously in recent decades, from the 1G analog networks and bulky cellular devices of the 1980s to the 5G networks that currently support our ultra-fast Internet and Internet of Things (IoT) connectivity. At the foundation of all this mobile communication are antennas, effectively the bridge between electronic devices and wireless networks. Now, as we prepare to enter into a new era of 6G network technology—defined by even faster speeds, ultra-low latency, and more sophisticated IoT devices—the demand for higher-performing antennas is increasing, along with the demand for raw materials used in antenna production, such as silver and other precious metals. 

In light of this antenna market growth, the question of cost and sustainability is paramount. Specifically, we must contend with how to meet this increasing production demand while mitigating environmental impact and cost challenges through the reduction of valuable raw material consumption and energy usage. Sweden-based DP Patterning, inventor of the Dry Phase Patterning (DPP) manufacturing process for flexible electronics, is positioning its technology as a solution.  

The hurdles on the road to green antennas

Methods like wet chemical etching, and silver ink printing have traditionally been used to manufacture antennas. Unfortunately, these processes fall short when it comes to sustainable antenna production. As Duncan Platt, Unit Manager of Printed Electronics at the Research Institute of Sweden (RISE), explains: “Wet etching and chemical-based processes generate hazardous waste and consume significant amounts of water and energy. Silver ink printing, for its part, requires several steps—printing, drying, and curing—that take time and add complexity.” 

“DP Patterning provides a cleaner, lower-energy, chemical-free process. The metal swarf removed by milling is recyclable. According to an independent study conducted by the Fraunhofer Institute, the DP Patterning solution, if applicable, can reduce the equivalent carbon dioxide footprint by approximately 98%.”
Duncan Platt, Unit Manager of Printed Electronics at the Research Institute of Sweden (RISE)

Common antenna production approaches are also plagued by other challenges. For instance, CNC milling is notoriously slow, which limits the scalability and throughput of antenna production in high-volume applications. From a material standpoint, the use of conductive materials like silver inks can drive up production costs, particularly as material prices are subject to market volatility. “The supply of printed circuit boards and precious metals like silver can present sourcing issues in times of geopolitical turbulence,”  Duncan emphasizes. “Furthermore, printed silver traces often achieve only 10–30% of bulk silver conductivity, affecting performance.”

Meeting the growing demand for high-performance antennas required for widespread 6G rollout—in a sustainable way—thus requires a different approach, one that delivers on scale, cost, and efficiency. That’s where Dry Phase Patterning comes in. 

DPP unlocks sustainability, cost savings, and productivity

DP Patterning’s patented DPP technology offers an alternative to more conventional antenna production techniques that is more sustainable, cost-efficient, and productive. 

The technology is based on a roll-to-roll mechanical milling process that uses a cliché to pattern an aluminum, copper, or copper-clad aluminum laminate. Once the pattern (with a minimum gap width of 100 µm and pattern pitch down to 400µm) has been applied to the laminate, a precision milling wheel mills away the pattern from the top layer of the laminate, resulting in a substrate with conductive traces. As a mechanical process, DPP does not require the use of any hazardous chemicals, inks, or freshwater. On top of that, the metal removed in the milling process can be fully recycled, resulting in virtually no waste.

Duncan explains the ecological significance of this process: “DP Patterning provides a cleaner, lower-energy, chemical-free process. The metal swarf removed by milling is recyclable. According to an independent study conducted by the Fraunhofer Institute, the DP Patterning solution, if applicable, can reduce the equivalent carbon dioxide footprint by approximately 98%.”

DPP is also more cost-efficient than competing processes for antenna design and production. This is primarily driven by material costs, as aluminum is far cheaper and more cost stable than bulk copper and silver. DP Patterning reports that companies can significantly reduce costs by using aluminum laminate instead of silver ink. 

Of course, conductivity is an important consideration for any antenna, and copper is king when it comes to this specific property. With this in mind, Duncan specifies that DP Patterning can provide patterned aluminum with conductivity levels equivalent to conventional copper printed circuit boards if that level of conductivity is required simply by increasing the design thickness. Generally, though, a standard aluminum substrate provides a sufficient degree of conductivity (for example, the standard 9µm thick aluminium can reach two to three times the conductivity of printed silver ink). In tests comparing a DPP RFID tag to a conventional RFID tag, DP Patterning found that they had the same frequency range, while the former also benefited from a smaller CO2 footprint.

In terms of productivity, DPP has the capacity to produce up to 30 meters of patterned single-layer substrate per minute—up to 10 times faster than conventional processes. Using a magnetic roll-to-roll system and an easy-swap tooling system, DP Patterning’s solution can also easily switch between pattern designs, unlocking design flexibility and customization. The rate at which DPP hardware can turn out antennas is also reinforced by the fact that antenna manufacturers can benefit from localized production thanks to DP Patterning’s micro plants, minimizing the reliance on unstable global supply chains and dramatically reducing lead times and emissions associated with logistics and transport. 

DPP antenna applications 

Antenna geometries and topologies vary greatly depending on performance factors like signal strength and frequency range, as well as overall goals like durability, sustainability, and cost. DP Patterning’s technology is equipped to manufacture a range of different antenna designs, from miniaturized, mass-produced antennas integrated into IoT devices, to large-area array antennas used for radar and satellite communications.

The table below covers a selection of the antenna types that Dry Phase Patterning is well-suited for:

“Antennas are almost ubiquitous these days so the DP Patterning technology can support the innovation drive, as a sustainable alternative, towards all kinds of applications with a growing demand for high-performance, low-cost antennas, such as 5G/6G, smart infrastructure, and more,” Duncan says. Looking forward, DPP technology could play an important role in transitioning antenna manufacturing towards greater efficiency and sustainability. 

Are you attending the European Microwave Week? Visit DP Patterning at Stand B138 to learn more about DP Patterning’s patented DPP technology and how it can benefit the manufacturing process for specific antenna applications, get in touch with us company today.