AuraGuard 5G‑ISAC System-on-Chip is a single system‑on‑chip that fuses millimetre‑wave radar sensing, ultra‑reliable low latency 5 G communication and safety‑certified logic, transforming every collaborative robot into a perceptive, context‑aware teammate. A 100 MHz, 60 GHz OFDM waveform simultaneously illuminates operators’ hands for sub‑centimetre gesture capture and transports encrypted emergency‑stop packets with sub‑50 ms end‑to‑end delay, compressing cameras, LiDARs and fieldbus lines into one radio.

A 4 × 4 phased‑array front‑end steers beams adaptively, while pilot‑guided MIMO processing, micro‑Doppler extraction and a lightweight k‑nearest‑neighbour engine sustain >95 % gesture accuracy within 150 ms at only 8 dB SNR. Running in parallel, a hardened co‑processor executes ISO 10218‑1/2 and ISO/TS 15066 speed‑and‑separation equations every 66 ms, refreshes multi‑tier safety envelopes at >15 Hz and issues velocity‑scaling or jerk‑bounded stops through deterministic real‑time Ethernet. Exhaustive simulation verifies that minimum human‑robot distance never breaches regulatory thresholds. A flexible processor subsystem orchestrates tasks, and shared on‑chip memory with DMA keeps bandwidth use below 65 %, preserving headroom for AI‑assisted perception or predictive maintenance add‑ons. Unified Gesture‑Safety Intelligence yields dramatic productivity and safety gains: on a high‑mix electronics line, a two‑finger “fetch” gesture dispatches a cobot while its adaptive zone contracts to let a technician solder within 20 cm; in heavy‑equipment assembly, a raised palm queues a 50 kg panel lift and the protection bubble widens as the arm accelerates. Inside a cold store, a swipe reroutes mobile robots and radar pre‑emptively decelerates them when forklifts appear from blind aisles. Digital‑twin evaluations across these scenarios log 18–30 % cycle‑time reductions, zero near‑miss incidents and a 12 % uplift in overall equipment effectiveness.

With processing pipelines clocked at multi‑gigabit baseband rates and worst‑case safety‑loop closure measured at 4.8 ms, AuraGuard delivers class‑leading performance‑per‑watt: 35 % energy savings over discrete multi‑sensor stacks. Firmware‑defined resource mapping lets integrators toggle between sensing‑centric and data‑centric modes or scale to 8 × 8 MIMO and richer gesture vocabularies without silicon respin, future‑proofing investment. The design is pin‑compatible with reconfigurable FPGA boards for rapid prototyping and migrates seamlessly to cost‑optimised ASIC silicon for mass adoption. RF sensing preserves worker privacy, thrives in glare, dust and weld spatter where optics fail, and coexists with AGV and AMR fleets thanks to intrinsic electromagnetic compatibility. By collapsing vision, radar and safety PLC functions into one standards‑compliant die, AuraGuard slashes system cost by 40–55 %, delivers a two‑year payback for SMEs and unlocks a high‑margin platform business for cobot, AMR and industrial‑IoT suppliers. These validated metrics prove AuraGuard’s capacity to unleash safer, faster and greener automation on a global scale.