Bioinspired Directionally Porous Alumina Ceramics With High Reflectivity and Strength for Extreme Laser Protection

High-energy laser protection requires materials that combine ultrahigh reflectance with robust mechanical strength. Inspired by the anisotropic porous structure within the scales of the Cyphochilus beetle, this work proposes a “directionally porous photonic structure” design strategy for alumina ceramics. Using a rolling–extrusion process, we successfully construct a highly aligned network of flattened pores within the ceramic matrix. This bioinspired architecture achieves a reflectance exceeding 99% at the 1070 nm wavelength and exhibits exceptional laser protection capability, withstanding 60 s of continuous laser irradiation at a power density of 3500 W/cm² without surface damage. The material also exhibits excellent thermo-mechanical stability under repeated thermal cycling. Moreover, the uniform, fine-pore structure enables a high compressive strength of 330 MPa at 38.5% porosity, surpassing other porous alumina ceramics of comparable porosity. This study provides a novel bio-inspired design concept and a feasible fabrication route for developing high-performance laser-protection materials capable of functioning in extreme environments.