Computationally-efficient synthesis of inversely-designed 3D-printable all-dielectric devices

We present a systematic, computationally efficient approach for synthesizing 3D-printable all-dielectric devices. Inverse-design optimization methods lead to devices of a continuous dielectric constant profile with complex and conformal shapes. However, stereolithography 3D printers have a limited range of materials; usually, only resin and air are available. As the size and complexity of the devices increase, performing simulations of the entire detailed manufacturable device becomes computationally challenging or even prohibitive. We introduce the LOCABINACONN methodology for transforming an optimized device of a continuous material profile to a manufacturable one while preserving performance as close as possible to the continuous case. The LOCABINACONN is a local and computationally efficient methodology where we identify suitable air/resin configurations that will substitute non-manufacturable material components without simulating the entire manufacturable device. This work paves the way for synthesizing optimized larger-scale 3D-printable devices in a computationally tractable manner.