Automated generation of high-accuracy CAD models for metaform design, fabrication, and testing

Metaforms are novel optical components formed by conforming a metasurface to a freeform substrate. Metaforms can be a powerful solution when designing compact imaging systems such as augmented reality displays. Given the rotationally variant nature of the metaform substrate and the difficulty of metasurface fabrication on curved substrates, the proper alignment of the metasurface nanofeatures to the freeform substrate is essential. Thus, to seamlessly bridge the metaform design, manufacturing, and metrology, we developed a software tool that automatically generates ISO standard highaccuracy CAD models for the designed metaform components.