What if you could ride light like a sailboat rides the winds across the ocean? While this concept may seem impossible, it’s feasible thanks to several scientific developments over the years. Recent breakthroughs in AI-optimized lightsails could hold the key to projecting man’s reach across the galaxy. Here’s what you need to know
What Are Lightsails? The Future of Space Propulsion Explained
When you visualize deep space travel, it’s likely you picture a spacecraft with thrusters or some form of ionic boost system like those seen in famous sci-fi shows. While these options have been under development for decades, one concept has been around for hundreds of years and is just now getting its day in the sun: light sails.
The idea to create a craft that could ride the waves of light to traverse the galaxy goes back to 1608. It was at this time that two now-famous inventors, Johannes Kepler and Galileo Galilei, discussed the idea.
According to the history books, Kepler was inspired one night after watching how a comet’s tail pointed away from the Sun. He concluded that it would one day be this tail projecting items through space rather than just following them.
First Real-World Lightsail Deployment: A 2019 Milestone
It wouldn’t be until 2019 that the first functioning lightsail made its way onto a spacecraft and operated properly. Earlier attempts saw the sail fail to open. In this instance, the lightsail was deployed and utilized to change direction in orbit. This moment marked the first time a light sail propulsion system functioned outside a lab.
How Do Lightsails Work? The Science Behind Photonic Propulsion
Lightsails come in many forms, but they all share some common traits. For one, they combine an ultra-thin reflective membrane that is propelled by light radiation. Notably, these sails are capable of achieving unmatched speeds, with some engineers claiming they want to achieve a fifth of the speed of light. This speed would allow mankind to travel to other suns and galaxies in decades versus the thousands of years it would take using traditional boost systems.
The Starshot Breakthrough Initiative: Shooting for Alpha Centauri
The idea of riding sun rays into deep space has seen strong support from some of the most intelligent and creative minds. The Starshot Breakthrough Initiative is a prime example of this support. The project was founded by Yuri Milner and the physicist Stephen Hawking.
They envisioned utilizing high-powered ground lasers to generate an optical force on a reflective, lightweight sail material. One day, this strategy will propel hundreds of low-mass microchip satellites into deep space. This network of advanced spacecraft will include a host of sensors like cameras, meters, and probes designed to provide real-time data to scientists at home.
Challenges Facing Traditional Lightsail Technology
The concept of lightsails opens the door for human exploration into deep space. However, there are still many issues and concerns that have made utilizing these devices a rarity. For one, it’s incredibly expensive to create lightsails. Traditional lightsails require years of advanced manufacturing techniques capable of creating nanoscale items using specific materials designed to hold up in orbit.
Another problem with today’s advanced lightsails is that they aren’t capable of scaling up. They can only be built at a nanoscale using today’s current methods. As such, they are unable to provide the same benefits to larger or even manned operations currently.
Lightsails also utilize a very specific geometry, including microscopic holes as a way to reduce weight. Like with traditional sails, less weight equals faster travel times and launches. However, the unique geometries and stringent performance requirements of lightsails make them very difficult to utilize on bigger projects.
AI-Optimized Lightsails: A Game-Changer in Deep Space Travel
Now, a team of researchers from Brown University and Delft University of Technology has unlocked a new AI-optimized lightsails fabrication method that could change everything. The “Pentagonal photonic crystal mirrors: scalable lightsails with enhanced acceleration via neural topology optimization,”1 published in Nature Communications, introduces an AI-assisted lightsail design and creation method that has the potential to upgrade the entire industry.
Inside the AI-Driven Lightsail Design Process
The engineers developed a new gas-based etch strategy utilizing ultra-thin, ultra-reflective membranes made of single-layer silicon nitride. This approach delicately removes material under the sail until the desired thickness and shape are achieved.
In this instance, engineers designed a pentagonal lattice-based photonic crystal (PhC) reflector that offered lightweight performance and durability. The lightsail was 2.4 inches long. Insanely, the engineers were able to achieve 200 nanometers in thickness. This measurement means that this sail is much thinner than a strand of human hair, yet capable of handling significant pressure when installed.
Interestingly, the engineers decided to make the holes on the edge of the sail 3% larger than the holes located on the internal parts of the sail. This design causes the reflectivity to increase by shifting the reflectivity spectrum by 10-20 nm.
Source – Brown
Photonic Crystals and Silicon Nitride: Materials of the Future
All of the intricate designs are meant to maximize reflectivity in the sail. Reflectivity is what ensures light pressure can build up and project the craft. As such, it’s vital in determining performance, speed, and even start times. Recognizing this fact, the engineers utilized advanced AI to ensure they optimized reflectivity.
Researchers from Brown University and TU Delft created an AI-powered neural topology optimization model that could design and fabricate lightsails in record time and with unmatched performance. Combining recent breakthroughs in materials science, structural engineering, and optics allows engineers to create the largest and most effective lightsail ever.
The team took a unique approach because they utilized their AI system before finite element analyses. This strategy shifts the optimization problem to finding the weights and biases of the neural network, allowing engineers to achieve optimized shape, size, and placement.
Lightsails are intricately patterned with billions of nanoscale holes designed to increase reflectivity and reduce weight. These tiny holes are made to be smaller than the diameter of light rays, allowing them to direct light to generate force. Impressively, this approach improves performance, acceleration, and tolerance to Doppler shifts and reduces launch and manufacturing costs.
Breakthrough Fabrication: From Years to Days and 9000x Cheaper
The engineers tested their fabricated lightsail using a variety of methods to ensure it performed as planned. Notably, the team fabricated a 60 × 60 mm2, 200 nm thick reflector. The sail integrated +1B nanoscale features and was manufactured at a price equivalent to 9000-fold cheaper than traditional methods. Additionally, it only took a day to create versus decades using older methods.
Performance Testing of the AI-Engineered Lightsail
The test results proved that the new and improved lightsails offer better performance and are more affordable. The new fabrication process is scalable and could one day prove an invaluable part of interstellar travel plans. Additional data revealed that the new lightsail design was more rugged and sensitive to the light radiation that propels it.
One cool detail about this lightsail is that it was designed to offer bidirectional capability. Earlier lightsails could only go in the direction they were pointed when the light was applied. This design may offer greater directional flexibility due to its enhanced reflectivity profile.
From Lab to Launch: Real-World Applications of Lightsails
There are a lot of benefits that this lightscale fabrication will bring to the market. For one, it provides a reliable method to create the highest aspect ratio nanophotonic sail ever. This method can complete nanophotonic designs in under 24 hours. This time frame demolished older methods that took many years.
The Role of AI in Revolutionizing Space Materials
Another benefit of this study is that it opens the door for major innovations in the design, fabrication, and testing of these materials. Already, engineers have succeeded in creating the largest lightsail using this strategy. In the future, AI-optimized fabrication methods could help unlock a new level of innovation.
In the end, it all comes back to costs. This approach to lightsail manufacturing is thousands of times less expensive than alternatives. This manageable price will allow more scientists and researchers to integrate lightsails into their projects, driving adoption and research.
Meet the Researchers Behind the Lightsail Innovation
The AI-optimised lightsail study was led by co-authors Miguel A. Bessa and Richard A. Norte. They were assisted by colleagues from Brown University and Delft University of Technology. Specifically, Lucas Norder, Shunyu Yin, Matthijs H. J. de Jong, Francesco Stallone, Hande Aydogmus, and Paolo M. Sberna contributed to the report. Additionally, the experiment received funding from the European Union and a Limitless Space Institute I2 Grant.
In the coming months, Engineers hope to improve their sail design using more AI assistance to brainstorm experimental layouts. This system will allow engineers to leverage simulations to test different configurations of the billions of nanoscale holes designed to enhance reflectivity and reduce mass.
Lightsails and Interstellar Communication: The Next Frontier
Space travel is the primary application for these devices and the new fabrication methods engineers have developed. This breakthrough dramatically improves the feasibility of laser-driven interstellar space probes, making scalable, ultra-light nanophotonic sails possible. You could also see this manufacturing process used to create other light-powered devices in the future.
Advanced Communication Systems
Imagine thousands of tiny nanosatellites operating as a relay to send your message across galaxies. This feature isn’t too far off, as these systems will be self-powered and capable of surviving in the harsh outer space environment for decades.
Investing in Photonics
The photonics and nanofabrication markets are filled with companies that continue to drive innovation. These firms have spent significant amounts on R&D, allowing them to continually push the tech into new heights. Here’s one company that has secured a reputation as a leader in the photonics sector and more.
Applied Materials Inc (AMAT -5.09%) entered the market in 1967 as a chemical supply company. The company’s founder, Michael A. McNeilly, quickly shifted the firm’s focus to providing support to the building semiconductor market after the company had been open for only ten years. Today, Applied Materials is well-positioned to support the manufacturing of photonic crystals and advanced semiconductor materials used in spacecraft components.
Since its launch, Applied Materials has consistently made large-scale acquisitions, which have expanded its networks and offerings. Specifically, the company acquired Etec Systems, Opal Technologies, Baccini, and many others. Each acquisition deepened the firm’s market positioning and influence.
Applied Materials, Inc. (AMAT -5.09%)
Currently, Applied Materials operates the largest solar tech center in the world. Additionally, it remains a global leader in nanofabrication and photonics. As such, those seeking exposure in a reputable photonics manufacturer should continue their research into Applied Materials.
Latest on Applied Materials Inc
What’s Next for AI-Optimized Lightsail Technology?
There are still a few details that engineers will need to solve to take this technology from the lab into real-world use. For one, they need to continue to experiment with new and lighter materials to ensure that they can withstand the harsh environment of outer space.
Additionally, these systems have yet to be fully tested in orbit. As such, the next stage of the process will involve launching these tiny devices and monitoring their actions to ensure their performance meets the strict standards required for decades of interstellar flight and communications.
AI-Optimized Lightsails
If all goes well, AI-optimized lightsails have the potential to give humans a glimpse into other galaxies in as little as 10-20 years. These systems will also one day become the infrastructure for an interstellar communications network, connecting deep space colonies with home. For now, these engineers deserve praise for their forward-looking stance and ingenuity.
Learn about other Material Science Breakthroughs here.
Studies Referenced:
1. Norder, L., Yin, S., de Jong, M. H. J., Stallone, F., Aydogmus, H., Sberna, P. M., Bessa, M. A., & Norte, R. A. (2025). Pentagonal photonic crystal mirrors: Scalable lightsails with enhanced acceleration via neural topology optimization. Nature Communications, 16, Article 2753. https://doi.org/10.1038/s41467-025-57749-y