Height–slope co-design enables scalable 3D printing of high-performance, multifunctional metasurfaces

Precise and efficient wavefront control is essential for next-generation photonic systems. While metasurfaces provide a powerful platform, their implementation—particularly in the terahertz (THz) regime, which is vital for 6G communications, optical computing, and biomedical imaging—is often constrained by limited structural tunability, computationally intensive full-wave simulations, and complex fabrication processes. Here, we present a height–slope co-design strategy that enables the scalable 3D printing of high-performance, multifunctional metasurfaces. By introducing sidewall slope as an additional structural degree of freedom, the accessible design space is significantly expanded, enabling electromagnetic functionalities beyond those achievable with conventional width- or height-only modulation. A compact analytical model replaces brute-force parameter sweeps, accelerating the design process by over two orders of magnitude while maintaining high accuracy. Additionally, slope-assisted resonance tuning improves transmission efficiency, and integration with coating techniques enables broadband amplitude modulation and asymmetric transmission. The proposed strategy is experimentally validated through the design, fabrication, and characterization of a series of THz metasurfaces exhibiting enhanced beam control, mechanical stability, and spectral versatility. This geometric co-design approach provides a scalable and generalizable methodology for the rapid realization of multifunctional photonic components.