SP2RINT: Spatially-Decoupled Physics-Inspired Progressive Inverse Optimization for Scalable, PDE-Constrained Meta-Optical Neural Network Training

DONNs leverage light propagation for efficient analog AI and signal processing. Advances in nanophotonic fabrication and metasurface-based wavefront engineering have opened new pathways to realize high-capacity DONNs across various spectral regimes. Training such DONN systems to determine the metasurface structures remains challenging. Heuristic methods are fast but oversimplify metasurfaces modulation, often resulting in physically unrealizable designs and significant performance degradation. Simulation-in-the-loop optimizes implementable metasurfaces via adjoint methods, but is computationally prohibitive and unscalable. To address these limitations, we propose SP2RINT, a spatially decoupled, progressive training framework that formulates DONN training as a PDE-constrained learning problem. Metasurface responses are first relaxed into freely trainable transfer matrices with a banded structure. We then progressively enforce physical constraints by alternating between transfer matrix training and adjoint-based inverse design, avoiding per-iteration PDE solves while ensuring final physical realizability. To further reduce runtime, we introduce a physics-inspired, spatially decoupled inverse design strategy based on the natural locality of field interactions. This approach partitions the metasurface into independently solvable patches, enabling scalable and parallel inverse design with system-level calibration. Evaluated across diverse DONN training tasks, SP2RINT achieves digital-comparable accuracy while being 1825 times faster than simulation-in-the-loop approaches. By bridging the gap between abstract DONN models and implementable photonic hardware, SP2RINT enables scalable, high-performance training of physically realizable meta-optical neural systems. Our code is available at https://github.com/ScopeX-ASU/SP2RINT