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

TL;DR

This paper introduces a computationally efficient method for designing 3D-printable dielectric devices by transforming continuous material profiles into manufacturable configurations without extensive simulations.

Contribution

The paper presents the LOCABINACONN methodology, enabling the conversion of optimized continuous profiles into manufacturable designs suitable for limited-material 3D printing.

Findings

LOCABINACONN preserves device performance close to the ideal design.

Method reduces computational complexity for large-scale device synthesis.

Enables practical fabrication of complex dielectric devices.

Abstract

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.