Methods are provided for producing large volumes of
small antenna arrays. In one embodiment, the method comprises the steps of creating an
antenna array pattern as a
computer file, printing the created pattern onto the surface of a suitable transfer paper, placing the printed image surface in contact with the surface of a material to be etched, and transferring the printed image to the surface of the material to be etched. The transfer can be effected by any combination of chemicals, heat, and / or pressure. After transfer of the printed image, the transfer paper is removed. The step of removing the transfer paper optionally includes
wetting the transfer paper in a manner that dissolves the transfer paper leaving the printed antenna pattern on the surface of the material to be etched. The method further includes the step of
etching the non-printed portions of the material, preferably by chemical
etching, and removing the printed pattern from the surface of the material to yield an
antenna array comprising a non-etched portion of the
substrate surface. Arrays, and substrates having an etch-resistant
mask for making the arrays, are also provided.