Electromagnetic metasurfaces have shown immense potential for wave control in diverse frequency regimes ranging from radio frequencies to the visible. In visible frequencies, materials with low loss and the ability to tightly confine light (high-index dielectrics, plasmonic metals) become limited. Optical metasurfaces are additionally challenging from a practical point of view, since they require nanofabrication techniques with high resolution and precision. Here, we consider polymer-based optical metasurfaces to be fabricated with two-photon lithography, which is a fast, scalable and cost-effective nanofabrication technique. We focus on a beam steering scenario, which is the archetypical example of wavefront manipulation functionalities. The proposed design operates in transmission and the principle of operation is based on phase accumulation within short vertical waveguide segments. We start from idealized, perfectly-cylindrical meta-atom shapes, which are typically studied in the literature, and proceed to conical shapes which exhibit increased mechanical stability and smooth half-ellipsoid-like structures that are compatible with the voxels of the laser writing process. We show that the adopted realistic meta-atom shapes lead to only a small deterioration of the steering performance and by employing numerical optimization we are able to recover the performance obtained with the idealized meta-atom shapes. Our work aspires to enable high-performance, practical optical metasurfaces taking fabrication limitations and particularities thoroughly into account.
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