Pentagonal Photonic Crystal Mirrors: Scalable Lightsails with Enhanced Acceleration via Neural Topology Optimization

The Starshot Breakthrough Initiative aims to send one-gram microchip probes to Alpha Centauri within 20 years, using gram-scale lightsails propelled by laser-based radiation pressure, reaching velocities nearing a fifth of light speed. This mission requires lightsail materials that challenge the fundamentals of nanotechnology, requiring innovations in optics, material science and structural engineering. Unlike the microchip payload, which must be minimized in every dimension, such lightsails need meter-scale dimensions with nanoscale thickness and billions of nanoscale holes to enhance reflectivity and reduce mass. Our study employs neural topology optimization, revealing a novel pentagonal lattice-based photonic crystal (PhC) reflector. The optimized designs shorten acceleration times, therefore lowering launch costs significantly. Crucially, these designs also enable lightsail material fabrication with orders-of-magnitude reduction in costs. We have fabricated a 60 x 60 mm$^2$, 200nm thick, single-layer reflector perforated with over a billion nanoscale features; the highest aspect-ratio nanophotonic element to date. We achieve this with nearly 9,000 times cost reduction per m$^2$. Starshot lightsails will have several stringent requirements but will ultimately be driven by costs to build at scale. Here we highlight challenges and possible solutions in developing lightsail materials - showcasing the potential of scaling nanophotonics for cost-effective next-generation space exploration.