A method of forming a flat panel array antenna includes the steps of: (a) providing a digitized design for a flat panel array, the flat panel array comprising a plurality of geometric features that vary in area along a thickness dimension of the flat panel array; (b) subdividing the digitized design into a plurality of thin strata stacked in the thickness dimension; (c) forming a thin layer of material corresponding to one of the thin strata; (d) fixing the thin layer of material; and (e) repeating steps (c) and (d) to form a flat panel array.