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In this work, we present a reproducible suite of test problems for large-scale optimization (“inverse design” and “topology optimization”) in photonics, where the prevalence of irregular, non-intuitive geometries can otherwise make it challenging to be confident that new algorithms and software are functioning as claimed. We include test problems that exercise a wide array of physical and mathematical features—far-field metalenses, 2d and 3d mode converters, resonant emission and focusing, and dispersion/eigenvalue engineering—and introduce ana posteriorilengthscale metric for comparing designs produced by disparate algorithms. For each problem, we incorporate cross-checks against multiple independent software packages and algorithms, and reproducible designs and their validations scripts are included. We believe that this suite should make it much easier to develop, validate, and gain trust in future inverse-design approaches and software.

 

Programming structures to realize any prescribed mechanical response under large deformation is highly desired for various functionalities, such as actuation and energy trapping. Yet, the use of a single material phase and heuristically developed structural patterns leads to restricted design space and potential failure to achieve specific target behaviors. Here, through a free-form inverse design approach, multiple hyperelastic materials with distinct properties are optimally synthesized into composite structures to precisely achieve arbitrary and extreme prescribed responses under large deformations. The digitally synthesized structures exhibit organic shapes and motions with irregular distributions of material phases. Within the structures, different materials play distinct roles yet seamlessly collaborate through sophisticated deformation mechanisms to produce the target behaviors, some of which are unachievable by a single material. While complex in geometry and material heterogeneity, the discovered structures are effectively manufactured via multimaterial fabrication with different polydimethylsiloxane (PDMS) elastomers with distinct behaviors and their highly nonlinear responses are physically and accurately realized in experiments. To enhance programmability, the synthesized structures are heteroassembled into architectures that exhibit highly complex yet navigable responses. The proposed synthesis, multimaterial fabrication, and heteroassembly strategy can be utilized to design function-oriented and situation-specific mechanical devices for a wide range of applications.