How do you turn a flat piece of nanostructured material into a secure biometric sensor?

In this episode, we speak with Rob Devlin, co-founder and CEO of Metalenz, about how metasurfaces are transforming optics and enabling a new generation of biosecure sensing. Devlin explains how engineers can control light at the subwavelength scale to replace bulky lens stacks with a single flat surface, and why the real breakthrough isn’t just miniaturization, but the ability to mass-produce optics in semiconductor fabs.

We explore how Metalenz scaled metasurfaces from academic prototypes into millions of devices, and what it takes to design optics for manufacturing. Devlin breaks down the transition from building one perfect device in a cleanroom to producing millions that all meet tight specifications.

The conversation focuses on polarization imaging as a new information channel in consumer devices. Unlike traditional cameras that capture only intensity and color, polarization reveals material properties. This enables a new approach to facial recognition that is both more secure and more compact than existing systems.

Rob also shares the story behind Metalenz, from its origins in a Harvard lab to partnerships with major semiconductor manufacturers, and how the company navigated the challenges of finding product-market fit, scaling fabrication, and building a new sensing stack from scratch.

Whether you’re interested in optics, nanofabrication, consumer electronics, or the future of biometric security, this episode explores how controlling light at the nanoscale is opening entirely new possibilities for sensing and identity verification.

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Timestamps:
00:00 - Intro
01:22 - Making Metalenses Mass-Producible
10:58 - Metasurfaces for Polarimetry
17:10 - Face ID Security and Pitfalls
24:47 - Polar ID Principles
29:02 - Polar ID Demo
39:58 - Meeting Federico Capasso
50:43 - Developing Metasurface Fabrication Techniques
55:58 - Founding Metalenz 
1:11:44 - Future of Metalenz and Metasurfaces

#photonics #faceid #biometrics #metasurface #biosecurity #optics