Metalens and Metamaterial Camera Optical Limitations AI-pedia

A comprehensive examination of metalenses and optical metamaterials, detailing their operational physics, engineering mechanisms, and the severe optical, physical, and manufacturing constraints that limit their deployment in consumer camera systems.

4,367 words · about 19 minutes to read · revised 13 November 2026 · written with gemini-3.8-flash-tiered

🤖 Written by Wren, the chat's AI, building on Wikipedia and on questions people asked in the chat. AI writing can be wrong or out of date: check anything that matters with a reliable source.

At a glance
Optical categoryFlat optics and planar metasurfaces
Key operational mechanismSub-wavelength phase and polarization control via dielectric or metallic nanostructures
Common visible-light materialsTitanium dioxide (TiO2), gallium nitride (GaN), silicon nitride (Si3N4)
Common infrared materialsAmorphous silicon (a-Si), polycrystalline silicon, germanium (Ge)
Primary chromatic bottleneckFundamental time-bandwidth (group delay) limit on achromatic aperture scaling
Diffraction resolution limitAbbe diffraction limit, defined as lambda / (2 * NA)
Off-axis optical aberrationsSevere angular sensitivity, coma, astigmatism, and field curvature
Fabrication technologiesDeep ultraviolet (DUV) photolithography, electron-beam lithography (EBL), nanoimprint lithography (NIL)
Typical commercial deploymentsSingle-wavelength near-infrared sensors, structured light projectors, endoscopes

A metalens is a flat optical device that uses an engineered array of sub-wavelength structures, known as a metasurface, to focus and manipulate light. Unlike conventional optical lenses, which rely on the curved shape and thickness of polished glass or molded plastic to gradually bend light through refraction, a metalens alters the wavefront of light across an interface that is only a few hundred nanometers thick. This technology emerged from research into metamaterials—artificial media structured with features smaller than the wavelength of light to exhibit electromagnetic properties not found in nature.

The prospect of replacing complex, multi-element camera lens assemblies with a single, paper-thin planar surface has attracted massive commercial interest from consumer electronics and photography manufacturers. Standard smartphone cameras and digital single-lens reflex (DSLR) systems require stacks of bulky curved glass or plastic elements to cancel out optical distortions, contributing significantly to device thickness, weight, and production complexity. In theory, a properly designed metasurface can control the phase, amplitude, and polarization of light simultaneously, offering a path toward ultracompact cameras.

In practice, fundamental physical laws, severe optical aberrations, and manufacturing limits currently prevent metalenses from replacing multi-element glass systems in general-purpose consumer cameras. While metalenses perform exceptionally well in monochromatic and narrowband infrared applications, deploying them across the full visible spectrum (400 to 700 nanometers) over wide field angles introduces steep drop-offs in resolution, image contrast, and optical transmission efficiency. These constraints arise from immutable relationships between optical bandwidth, lens diameter, and nanostructure group delay.

Historical Development and the Superlens Concept

The theoretical foundations of metamaterial optics were laid in 1967 by Russian physicist Victor Veselago. Veselago published a theoretical study examining electrodynamics in hypothetical materials possessing simultaneously negative electric permittivity (ε) and negative magnetic permeability (μ). He concluded that such substances would exhibit a negative refractive index, causing light to bend in the opposite direction to that predicted by standard Snell's law formulations, and would reverse the Doppler effect and Cherenkov radiation.

Veselago's work remained largely theoretical for three decades because natural materials do not exhibit negative permeability at optical frequencies. In 1999 and 2000, British physicist John Pendry proposed practical designs using artificial non-magnetic structures—such as arrays of thin wires and split-ring resonators—to achieve negative permittivity and permeability artificially. In 2000, Pendry published a seminal paper demonstrating that a thin slab of negative-index material could act as a "superlens" capable of overcoming the classical Abbe diffraction limit.

The Abbe diffraction limit, established by Ernst Abbe in 1873, states that conventional optical systems cannot resolve two objects separated by a distance smaller than approximately half the wavelength of the illuminating light (λ / (2 × NA), where NA is the numerical aperture). This limit occurs because fine sub-wavelength spatial details are carried by evanescent waves—electromagnetic fields whose amplitudes decay exponentially with distance from the object. Because evanescent waves do not propagate into the far field, conventional glass lenses collect only the propagating waves, losing the fine spatial information. Pendry showed that a negative-index slab, or even a thin film of metal exhibiting negative permittivity (such as silver), could amplify and restore these decaying evanescent waves, reconstructing images with sub-diffraction detail.

In 2005, Xiang Zhang's research group at the University of California, Berkeley, experimentally verified the superlens principle by imaging sub-diffraction features using a 35-nanometer silver slab under ultraviolet light. However, three-dimensional bulk metamaterials and superlens slabs suffered from severe physical constraints: high internal energy absorption (ohmic loss) in the metal layers, extreme difficulty in fabricating three-dimensional nanostructured blocks, and the requirement that the object remain within the near-field region (a distance smaller than one wavelength from the lens surface).

To overcome the losses and fabrication hurdles of bulk 3D metamaterials, researchers led by Federico Capasso at Harvard University pivoted in 2011 toward two-dimensional metamaterials, or metasurfaces. In their 2011 paper, Capasso and his team formulated the generalized laws of reflection and refraction. By arranging an ultrathin array of metallic or dielectric phase-shifting elements across an interface, they introduced a discontinuous phase gradient that could steer and shape propagating wavefronts in the far field without relying on bulk material thickness. This marked the birth of the modern metalens.

Operating Principles of Metasurfaces

A metalens achieves focusing by imposing a spatially varying phase shift on an incident plane wave, redirecting the wavefront to converge at a designated focal point. In standard geometrical optics, a curved convex glass lens achieves this because light travels more slowly in dense glass than in air; the thicker center of the lens delays the central portion of the wavefront more than the thin edges, creating a curved, converging wavefront. A metalens accomplishes the identical wavefront curvature on a completely flat substrate by altering the local phase shift at each discrete coordinate.

To focus a normally incident beam of light of wavelength λ to a focal point at distance f without spherical aberration, the required hyperbolic phase distribution Φ(r) as a function of the radial distance r from the lens center is:

Φ(r) = (2 * π / λ) * (f - sqrt(r^2 + f^2))

Here, r represents the distance from the optical axis, f is the target focal length, and λ is the design wavelength. To construct this phase profile across a planar substrate, the surface is divided into a grid of sub-wavelength unit cells, each occupied by a nanostructure—frequently shaped as a cylinder, rectangular fin, or cross. These nanostructures are referred to as "meta-atoms" or "nanopillars."

Phase Modulation Mechanisms

Metasurfaces impart phase shifts to incoming photons using three primary physical mechanisms:

The Chromatic Aberration Bottleneck

The single greatest obstacle preventing metalenses from replacing multi-element glass lenses in consumer photography is chromatic aberration. Chromatic aberration occurs when an optical element fails to focus different wavelengths (colors) of light to the same spatial focal point, resulting in severe color fringing, severe blur, and lost resolution.

Conventional refractive glass displays "normal dispersion," meaning the refractive index of glass decreases slightly as the wavelength increases (blue light bends slightly more than red light). In contrast, single-layer metalenses suffer from extreme negative diffractive dispersion. Because the phase shift profile is tied mathematically to the operational wavelength λ, a phase profile designed for green light will bend red light much more drastically than blue light. The focal length of an uncorrected diffractive metalens is roughly inversely proportional to the wavelength (f(λ) ≈ f0 * λ0 / λ). Over the visible spectrum (400 to 700 nanometers), an uncorrected metalens will focus blue light nearly twice as far away from the lens as red light, completely destroying full-color image fidelity.

Group Delay and the Achromatic Time-Bandwidth Limit

To eliminate chromatic aberration and construct an "achromatic metalens" that brings all visible wavelengths to the same focal spot simultaneously, every sub-wavelength unit cell on the metasurface must satisfy two distinct requirements simultaneously across the entire target frequency band ω:

  1. It must provide the correct phase Φ(r, ω) required to bend the light to the focal point at each frequency.
  2. It must match the arrival time of light packets traveling from different radial positions on the lens to the focal point. This property is known as group delay (Tg), defined as the first derivative of phase with respect to angular frequency: Tg(r) = dΦ(r, ω) / dω.

Because light traveling from the rim of a lens has a longer physical distance to travel to the focus than light traveling down the center axis, the center of the lens must hold the light back. The center nanostructures must provide a large group delay, while the edge nanostructures provide minimal group delay.

This requirement imposes an unavoidable physical ceiling known as the Presutti-Monticone limit (and related bounds derived by David A. B. Miller). The group delay an isolated dielectric nanostructure can provide is strictly limited by its physical height, its material refractive index, and the optical quality factor (Q) of its internal modes. A taller nanopillar can hold light longer, but manufacturing techniques limit pillar heights. Mathematically, for an achromatic metalens covering an angular frequency range Δω with a numerical aperture NA and a lens radius R, the minimum required group delay difference between the center and edge is:

ΔT_g = (R / c) * ( (1 / NA) - sqrt((1 / NA^2) - 1) )

Because the maximum achievable ΔTg is bounded by the aspect ratio and height of the nanostructures, an unyielding trade-off emerges: the product of the achromatic metalens diameter (2R), the numerical aperture (NA), and the spectral bandwidth (Δω) cannot exceed a fixed physical limit without requiring impossibly tall, high-aspect-ratio nanostructures.

For this reason, demonstrated broadband visible (400–700 nm) achromatic metalenses are physically restricted to tiny apertures—typically between 20 micrometers and 300 micrometers in diameter. A smartphone camera lens requires an aperture diameter of roughly 2 to 4 millimeters, while DSLR lenses require 25 to 80 millimeters. Scaling a single-layer achromatic visible metalens up to millimeter or centimeter scales while preserving high numerical aperture is mathematically impossible using single-resonance dielectric pillars.

Monochromatic and Off-Axis Aberrations

Even if chromatic aberration is ignored—such as under monochromatic laser illumination—metalenses face severe monochromatic aberrations when imaging objects located away from the central optical axis. These geometric aberrations include coma, astigmatism, spherical aberration, field curvature (Petzval curvature), and distortion.

Spatial Dispersion and Angle Sensitivity

A standard single-layer metalens is optimized for plane waves arriving at normal incidence (perpendicular to the metasurface). When light strikes the metasurface at an oblique angle θ, two failure modes occur:

Vignetting and Angular Efficiency Falloff

In conventional refractive photography, light intensity falls off toward the edges of an image frame according to the natural "cosine fourth law" (cos4(θ)). In metalenses, the intensity drop-off—known as vignetting—is drastically worse.

Because the sub-wavelength elements rely on capturing light within specific cross-sections, their coupling efficiency drops precipitously when incidence angles exceed 20 to 30 degrees. Rays arriving at steep angles fail to interact properly with the nanopillar cavities; instead of being focused, this light is either reflected away, absorbed, or scattered into random directions as stray background light. As a result, the optical efficiency of a metalens degrades rapidly across the field of view, making wide-angle photography (such as smartphone wide cameras with 80-degree fields of view) exceptionally poor without complex auxiliary optics.

Doublet and Multi-Metasurface Corrections

In classical optical engineering, off-axis aberrations are corrected by adding multiple lens elements with opposing curvatures (such as the historical Cooke triplet design). Metasurface engineers attempt a similar solution by fabricating "metalens doublets"—placing one metasurface on the front side of a transparent substrate to act as an aberration corrector and aperture stop, and a second metasurface on the back side to provide optical focusing power.

While doublets expand the field of view up to approximately 40 or 50 degrees without severe coma, they introduce new compromises. They double the fabrication complexity, mandate near-zero misalignment tolerances between the front and back nanostructure layers, introduce internal reflections between the substrates, and double the surface transmission losses. Furthermore, doublet systems still do not solve the fundamental time-bandwidth limit governing broadband chromatic aberration.

Efficiency, Stray Light, and Image Contrast

In consumer photography, a lens must deliver high resolution and high image contrast, measured scientifically via the Modulation Transfer Function (MTF). The MTF measures how faithfully the lens transfers spatial detail and contrast from the subject to the digital image sensor. Metalenses consistently suffer from poor MTF characteristics and low contrast due to stray light, background haze, and parasitic diffraction orders.

Optical Phenomenon Physical Manifestation in Metalenses Impact on Image Quality
Zero-Order Transmission A fraction of incident photons passes through the metasurface unmodulated without acquiring the target phase shift. Acts as a uniform, unfocused white background glare across the sensor, drastically lowering overall contrast.
Higher Diffraction Orders Light scatters into unintended spatial frequencies due to phase quantization errors across discrete unit cells. Creates ghost artifacts, secondary false images, and severe multi-point flare around bright highlights.
Diffuse Surface Scattering Rough sidewalls, etched structural variations, and nanostructure rounding scatter light randomly. Produces a cloudy, low-contrast haze over the entire image frame, severely depressing the MTF curve.
Polarization Cross-Talk Geometric-phase (PB) metasurfaces convert only circularly polarized light of the opposite helicity correctly. Unconverted polarization states pass straight through as unfocused background noise, losing 50% or more of natural light.

Even advanced dielectric metalenses operating under laboratory conditions often exhibit absolute optical transmission efficiencies between 50% and 75% across the visible spectrum. By comparison, a high-quality multi-element photographic glass lens coated with modern anti-reflective coatings transmits greater than 98% of incident visible light per element, delivering an aggregate assembly transmission exceeding 90% across the full visible spectrum.

Material Science and Manufacturing Constraints

The physical performance of a metalens depends on the optical properties of the materials used to construct its nanostructures. To manipulate light efficiently without losing energy, the chosen material must possess a very high refractive index (to tightly confine light inside narrow structures) and an extinction coefficient (k) near zero across the entire target wavelength range (indicating zero optical absorption).

Material Refractive Index (n) at 550 nm Bandgap (eV) Optical Absorption (400–700 nm) Primary Fabrication Challenge
Titanium Dioxide (TiO2) ~2.4 to 2.6 ~3.2 Near-zero throughout visible spectrum Requires slow, expensive Atomic Layer Deposition (ALD) or cryogenic dry etching.
Gallium Nitride (GaN) ~2.4 ~3.4 Near-zero throughout visible spectrum Requires epitaxially grown crystal layers on sapphire or silicon; prone to sidewall roughness.
Silicon Nitride (Si3N4) ~2.0 ~5.0 Zero absorption; completely transparent Moderate index requires exceptionally tall pillars (aspect ratios > 1:12) to get 2π phase shift.
Amorphous Silicon (a-Si) ~4.0 ~1.6 Severe absorption below 650 nm (opaque to blue and green) Cannot be used for broadband visible cameras; restricted to near-infrared (NIR) and telecom.
Hafnium Dioxide (HfO2) ~2.1 ~5.7 Zero absorption into near-UV Low refractive index requires extreme nanostructure heights; difficult dry etch chemistry.

The Aspect Ratio Dilemma

Because visible-light dielectrics like titanium dioxide and silicon nitride possess moderate refractive indices (between 2.0 and 2.5), a nanostructure must have a height of roughly 600 to 1,000 nanometers to accumulate a full 2π propagation phase delay. Concurrently, to satisfy the Nyquist sub-wavelength sampling criterion and avoid spurious diffraction, the unit cell pitch (the center-to-center distance between pillars) must be smaller than the wavelength divided by two—typically between 200 and 350 nanometers. This forces individual nanopillar widths to range between 50 and 150 nanometers.

Fabricating a 70-nanometer-wide pillar that stands 800 nanometers tall requires an aspect ratio exceeding 1:11. Structurally, these ultra-tall, narrow towers are mechanically fragile. During wet chemical processing, drying steps, or chemical mechanical planarization, surface tension forces cause capillary pull, leading to "stiction"—a catastrophic mechanical failure where neighboring nanopillars bend, touch, and adhere permanently to one another. Overcoming stiction requires advanced supercritical carbon dioxide (CO2) drying or embedding the pillars in low-index transparent polymers, which decreases the relative refractive index contrast and dampens phase accumulation.

Scalability and Lithography Economics

Early research metalenses were fabricated almost exclusively using Electron-Beam Lithography (EBL). EBL uses a focused beam of electrons to write nanometer-scale geometries sequentially onto an electron-sensitive resist. While EBL offers sub-10-nanometer resolution, it is an inherently serial raster-scanning process. Patterning a single metalens with a diameter of just 1 centimeter requires trillions of individual exposures, taking hours or even days of machine time per device. This makes EBL economically impossible for high-volume commercial manufacturing.

To commercialize metalenses, manufacturers adapt semiconductor fabrication lines using Deep Ultraviolet (DUV) immersion lithography (operating at 193 nm or 248 nm wavelengths). DUV processes expose whole wafers simultaneously using optical photomasks. However, DUV projection steppers are limited by optical proximity effects; when printing dense, heterogeneous arrays of 60-nanometer shapes with varying pitches across a wafer, optical diffraction blurs fine features, rounding sharp corners and shrinking pillar heights.

Nanoimprint Lithography (NIL) is an alternative mechanical replication method where a master mold stamps nanoscale patterns directly into a polymer resist. While NIL drastically reduces equipment costs compared to DUV steppers, the stamp masters wear out rapidly, and microscopic bubble defects or particle contamination cause local phase defects that ruin optical wave modulation across the lens.

Comprehensive Optical Architecture Comparison

To understand why traditional optics remain dominant in photography, the structural, optical, and industrial parameters of bulk refractive lenses, classical diffractive optical elements (DOEs), and dielectric metalenses must be evaluated side by side.

Metric / Feature Bulk Refractive Lens Stack Diffractive Optical Element (DOE) Dielectric Flat Metalens
Thickness Profile 5 to 50 millimeters (multi-element stack) 0.5 to 2 millimeters (thin surface relief) < 1 micrometer (on millimeter-thick substrate)
Phase Control Principle Continuous refractive delay via macroscopic surface curvature and thickness 2π phase wrapping via macroscopic surface profile steps Localized sub-wavelength resonant and waveguide phase shifts
Full Visible Chromatic Behavior Naturally low normal dispersion; corrected by pairing positive and negative Abbe glasses Severe negative dispersion; highly chromatic focal shift Extremely severe negative dispersion; fundamentally constrained by time-bandwidth limits
Broadband Visible Efficiency Very high (>90% overall transmission with anti-reflective coatings) Moderate to low across broad spectrum; high only at blaze wavelength Low to moderate (typically 50% to 75% due to scattering and material limits)
Off-Axis Aberration Handling Exceptional; multiple spaced elements cancel coma, astigmatism, and field curvature Poor; prone to severe flare and efficiency loss at high field angles Poor; severe spatial dispersion, coma, and rapid angular efficiency cutoff
Aperture Scalability Extremely high (millimeters to meters; limited only by mechanical glass polishing) High (easily molded onto large glass or plastic substrates) Extremely low for broadband achromatic designs (<1 mm); high only for monochromatic designs
Mass Manufacturing Process High-precision injection molding (plastic) or precision grinding/polishing (glass) Precision glass pressing or diamond micro-machining Semiconductor cleanroom processing (193 nm DUV lithography or Nanoimprint)
Relative Manufacturing Cost Cents to dollars per lens element at consumer scales Low to moderate at high volumes High; requires expensive cleanroom tooling, silicon wafers, and DUV masks

Current Viable Implementations and Niche Markets

Although metalenses cannot currently serve as the primary taking lens in a standard RGB smartphone camera or digital camera, they are finding practical, high-value commercial deployment in specialized optical domains where their unique properties bypass their physical limitations.

Near-Infrared (NIR) and Single-Wavelength Sensing

The most successful commercial deployments of metalenses avoid chromatic aberration entirely by operating under single-wavelength illumination, specifically in the near-infrared spectrum (850 nm and 940 nm). In these applications, the target illumination is provided by a vertical-cavity surface-emitting laser (VCSEL) with an exceptionally narrow spectral bandwidth (often less than 2 nanometers).

At these wavelengths, chromatic aberration is practically nonexistent because only one wavelength is ever present. Furthermore, amorphous silicon (a-Si) is transparent in the infrared while retaining an enormous refractive index of roughly 3.5 to 4.0. This allows engineers to build squat, mechanically robust nanopillars with low aspect ratios that are easy to etch. Products utilizing this approach include:

Endoscopy and Ultra-Miniature Biomedical Imaging

In medical endoscopy, a rigid camera probe must be threaded through blood vessels, internal tracts, or needles. Here, physical size and weight are paramount constraints, while optical color purity can be secondary or aided by narrowband sequential illumination (pulsing red, green, and blue LEDs sequentially rather than illuminating all simultaneously). Metalenses enable microscopic objective systems smaller than 1 millimeter in total diameter, offering high numerical apertures that conventional lens grinding cannot achieve at that physical scale.

Hybrid Refractive-Metasurface Optical Systems

Rather than attempting to eliminate traditional glass lenses entirely, optical engineers increasingly combine metalenses with conventional curved refractive lenses in hybrid assemblies. Because a single-layer metalens exhibits large negative chromatic dispersion, it behaves optically like an extreme "aberration compensator."

By placing one flat metasurface directly onto the flat rear surface of a standard positive curved glass lens, the extreme negative dispersion of the metasurface cancels out the positive dispersion of the glass. This hybrid approach enables optical designers to eliminate two or three glass elements from a telephoto or zoom stack while achieving achromatic correction, reducing total assembly weight without falling victim to the aperture-scaling bottlenecks of standalone metalenses.

Research Frontiers and Future Directions

To address the physical bounds that restrict metalenses, academic and industrial researchers are pursuing several computational and material strategies.

Inverse Design and Topology Optimization

Historically, metasurfaces were designed using a "forward design" library approach: an engineer simulated hundreds of isolated regular shapes (cylinders, squares), cataloged their respective phase shifts, and arranged them across a grid. This approach treats each nanostructure as an isolated waveguide, ignoring electromagnetic near-field coupling between adjacent, non-identical pillars.

Modern research relies heavily on inverse design through adjoint-based optimization and machine learning algorithms. In inverse design, the engineer defines the target far-field electromagnetic field distribution (e.g., broadband focusing at a specific numerical aperture) and allows computational algorithms to back-propagate the Maxwell equations iteratively. This produces continuous, non-intuitive, quasi-random topology patterns where the boundaries between individual meta-atoms blur. These deeply coupled structures extract higher operational group delays and wider field-of-view performance than isolated nanopillars, pushing performance closer to theoretical limits.

Computational Photography and Neural Reconstruction

Another prominent strategy offloads the burden of aberration correction from physical optics to post-processing software. Because modern image sensors are backed by powerful Image Signal Processors (ISPs) and Neural Processing Units (NPUs), cameras can photograph scenes using an aberrated, lightweight metalens and subsequently reconstruct the image algorithmically.

If the spatial and chromatic aberrations of a metalens are precisely mapped into a known Point Spread Function (PSF)—the mathematical description of how the lens blurs a point source of light across space and color—computational deconvolution algorithms can mathematically invert the blur. Deep convolutional neural networks trained on pairs of aberrated metalens images and ground-truth reference photos can remove residual chromatic fringing, boost MTF contrast, and eliminate background zero-order haze. However, computational post-processing introduces latency, consumes electrical power, can hallucinate fine textures, and amplifies sensor noise in low-light photography.

Reconfigurable and Dynamic Metasurfaces

Static metalenses cannot adjust their focus to track moving subjects. To introduce variable focus (autofocus) and optical zoom without mechanically moving physical elements, researchers are integrating active materials into metasurface substrates:

Current State and Consumer Outlook

The consumer electronics industry will not see conventional multi-element glass camera modules replaced by single-layer flat metalenses in the near future. The laws of electrodynamics dictate an uncompromising trade-off: a lens cannot simultaneously deliver an ultra-flat planar profile, a large light-gathering aperture, a wide field of view, and high-efficiency achromatic performance across the entire visible spectrum using current single-layer dielectric metasurface designs.

Instead, the integration of metalenses into consumer devices is proceeding incrementally. Over the coming years, metasurfaces will continue to dominate specialized single-wavelength modules, such as infrared facial mapping, proximity sensors, ambient light meters, and structured light projectors. In high-performance imaging, metasurfaces will operate primarily as specialized corrective layers deposited onto traditional curved glass elements, gradually shaving millimeters and grams off complex camera stacks rather than eliminating traditional optics entirely.

See also

Sources

Questions people asked

When can consumers expect metamaterial cameras to achieve high optical quality comparable to traditional glass lenses? — answered 13 November 2026

For narrow-band infrared or specific satellite channels, metalenses are already here in labs and niche sensors. But for a broadband visible camera (400–700 nm) with a decent aperture:

  1. Severe chromatic dispersion: A flat metasurface bends different wavelengths dramatically differently. Correcting full-spectrum RGB without adding back multi-layer refractive glass elements is mathematically brutal.
  2. Off-axis coma and vignetting: Metasurfaces work great at normal incidence, but image quality drops off a cliff as field angles widen.
  3. Aperture scaling and yield: Patterning trillions of sub-wavelength nanopillars over an inch or two without lithography defects is ludicrously expensive compared to grinding bulk glass.