Beyond Planar: An Additively Manufactured, Origami-Inspired Shape-Changing, and RFIC-Based Phased Array for Near-Limitless Radiation Pattern Reconfigurability in 5G/mm-Wave Applications

This letter presents an origami-inspired phased array operating at 28 GHz, with on-structure beamformer RFICs and a flexible feeding network that utilizes a foldable hinge interconnect. The mm-wave origami phased array therein operates at a substantially smaller scale compared with prior literature and achieves remarkable integration with on-structure beamforming circuitry. It introduces the first additively manufactured fully foldable hinge interconnect, exhibiting near-constant insertion loss across various folding angles and cycles. Leveraging origami principles, the phased array offers near 360° continuous beam steering in the azimuth plane with reconfigurable multibeam or quasi-isotropic radiation patterns. Additive manufacturing techniques, including 3-D and inkjet printing, are used to fabricate a low-cost and lightweight prototype. Measurements demonstrating near-limitless pattern reconfigurability due to mechanical shape change and electrical beam steering signify a significant leap in overcoming challenges faced by traditional phased arrays.

I. Introduction

The landscape of high-speed communications has undergone a revolutionary shift with the introduction of 5G mm-wave technology, unlocking unprecedented potentials for the development of smart cities, industry 4.0, and consumer focused IoT through broadband and ultrareliable low-latency communication. Nevertheless, the realization of the full potential of 5G mm-wave applications faces challenges, particularly because of the effectiveness of mm-wave signals, which experience significant deterioration in non-line-of-sight conditions due to the high path loss incurred. As such, the utilization of phased arrays has become imperative to 5G deployment, offering beam-steering capabilities that can reduce interference by the direct targeting of users. Traditional phased arrays, however, grapple with inherent limitations, primarily with their limited angular coverage and narrow beamwidths. Moreover, the bulkiness, cost, and rigidity of these systems hinder adaptability, making modification or replacement of subsystem components a formidable task.