We present a systematic approach for synthesizing 3D-printable all-dielectric devices. Inverse design approaches yield, in many cases, configurations with a continuous range of dielectric constant values. However, 3D printer resins usually provide a very limited set of such values; commonly, a single resin and air are the only available materials. We propose a methodology for transforming a device with a continuous range of material properties to a manufacturable one, while preserving the device’s performance as close as possible to the continuous case. We develop an algorithm that takes the continuous range of dielectric constant profile as input and generates a binary and connected device that can be 3D-printed using a single resin. Our methodology advances state-of-the-art algorithms by using manufacturable configurations of prescribed local air/resin composition to realize each designed dielectric material instead of being limited to a predetermined shape. The additional degrees of freedom provided by our approach may be particularly useful in devices of conformal complex-shaped dielectric constant profiles. We demonstrate the proposed methodology by designing a 3D-printable wide-angle refraction metagrating with performance very close to the inversely designed device of a continuous dielectric constant profile. The approach can be adapted to accommodate three-dimensional devices and other applications.
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