The aim behind this work is to design and manufacture a beam shaping lens for active terahertz imaging systems that boosts their performance in terms of sensitivity and image quality. The proposed beam shaper is based on an adaptation of the original optical Powell lens, where a collimated Gaussian beam is converted into a uniform flattop intensity beam. The design model for such a lens was introduced, and its parameters were optimized by a simulation study conducted using COMSOL Multiphysics software. The lens was then fabricated using a carefully chosen material [polylactic acid (PLA)] through a 3D printing process. The manufactured lens was implemented in an experimental setup to validate its performance using a continuous-wave sub-terahertz source around 100 GHz. Experimental results demonstrated a high-quality flattop beam maintained along the propagation path, which is highly recommended for terahertz and millimeter-wave active imaging systems to produce high-quality images.