Extreme nonlinearity by layered materials through inverse design

Biological materials such as seashell nacre exhibit extreme mechanical properties due to their multilayered microstructures. Collaborative interaction among these layers achieves performance beyond the capacity of a single layer. Inspired by these multilayer biological systems, we architect materials with free-form layered microstructures to program multistage snap-buckling and plateau responses—accomplishments challenging with single-layer materials. The developed inverse design paradigm simultaneously optimizes local microstructures within layers and their interconnections, enabling intricate layer interactions. Each layer plays a synergistic role in collectively achieving high-precision control over the desired extreme nonlinear responses. Through high-fidelity simulations, hybrid fabrication, and tailored experiments, we demonstrate complex responses fundamental to various functionalities, including energy dissipation and wearable devices. We orchestrate multisnapping phenomena from complex interactions between heterogeneous local architectures to encode and store information within architected materials, unlocking data encryption possibilities. These layered architected materials offer transformative advancements across diverse fields, including vibration control, wearables, and information encryption.