3D printing technologies for metasurface fabrication and applications of metasurfaces manufactured by 3D printing processes

Abstract

Metamaterials are artificial materials engineered to possess extraordinary properties, while metasurfaces represent their two-dimensional counterparts, capable of freely defining desired amplitude, phase, and polarization responses. Metasurfaces exhibit significant potential for miniaturizing, integrating, and multifunctionalizing optical devices. However, traditional micro-nano fabrication techniques face bottlenecks such as difficulties in manufacturing complex three-dimensional structures, poor material compatibility, high costs, and limited functionality. In recent times, the swift progress of 3D printing technology has sparked interest in its utilization for metasurface manufacturing. Noticing its characteristics of free-form fabrication design, multi-material integrated manufacturing, and programmable dynamic structures, 3D printing endows metasurfaces with high precision, low cost, and reconfigurable functionality, establishing it as a core pathway for next-generation metasurface production. This article reviews various 3D printing technologies applicable for fabricating metasurface devices and categorically introduces three application domains of metasurfaces prepared via these technologies. First, it presents the concepts of metamaterials and metasurfaces, as well as the merits of 3D-printed metasurfaces. Second, it elaborates on the characteristics, strengths, and applications of two-photon 3D printing, inkjet printing, and material extrusion 3D printing. Then, it classifies and discusses metasurfaces fabricated using 3D printing for three key application areas: singular beam generation, metasurface invisibility cloaks, and metasurface antennas. Finally, we give a summary and evaluation of 3D-printed metasurfaces.