Researchers at TU Delft and Brown University have developed a new class of ultra-lightweight, reflective nanomaterials originally designed for space exploration. At the heart of this innovation is a breakthrough in nanomanufacturing. The materials are just 200 nanometres thick—roughly 1/1000th the thickness of a human hair—yet span up to 60 mm, combining nanoscale fabrication with large-surface scalability. This high aspect ratio, paired with excellent reflectivity and surprising durability, enables potential uses in lightweight, optically active products and smart textiles.

Precision engineering meets design potential
The sails were created using a combination of nanofabrication techniques and AI-based topological optimisation, enabling unprecedented control over material properties. A novel fabrication layer allows for the selective removal of structural defects, making the films not only functional but also reliable under stress.

“Although these materials were originally designed for space, their unique properties—extreme thinness, stiffness, and reflectivity—could translate well into the worlds of advanced product and textile design,” says Dr Richard Norte, Associate Professor at TU Delft.

These nanomaterials could serve as reflective coatings for wearables, aesthetic smart surfaces, or ultra-light packaging materials. Their ability to manipulate light with precision could also be valuable in sensor integration, photonic textiles, or low-energy visual effects in product design.

From interstellar travel to scalable materials
The project is part of the Breakthrough Starshot Initiative, which aims to send nanocraft to the nearest stars using lightsails propelled by lasers. Traditional fabrication would take years, but using this new method, the team at TU Delft reduced production time to a single day. This leap in efficiency may also benefit terrestrial manufacturing, where speed and scale are critical.

Even at full scale, the nanomaterials remain robust and intact when suspended. If breakage does occur, it usually happens during production—not in use—demonstrating their potential reliability in commercial applications.

Dr Miguel Bessa of Brown University, who contributed to the project, emphasises the role of AI in design exploration: “By blending neural networks with topology optimisation, we’ve created designs that push the boundaries of what’s possible in both nanophotonics and large-scale manufacturing.”

“This research puts Delft at the forefront of nanoscale materials science,” says Norte. “It’s fascinating to explore what we can do when we make materials this thin, yet stable. These optical films could inspire new directions in how fast and efficiently we create design elements—across everything from sensors to smart fashion.”

Source: TU Delft
Photo: TU Delft