Strong interlayer coupling and chiral flat-band cascades in twisted bilayer gratings

From atomic crystals to macroscopic material structures, twisted bilayer systems have emerged as a promising route to control wave phenomena. In few-layer van der Waals (vdW) materials, however, the intrinsically weak interlayer coupling typically demands fine control of small twist angles to reach magic-angle conditions. Here, we show that one-dimensional photonic crystal bilayers can overcome this limitation by accessing a regime of strong interlayer coupling -- comparable to intralayer coupling. This strong coupling enables flat-band formation over a broad angular range even at large twist angles. We experimentally realize this regime by stacking WS$_2$ gratings using a two-step lithography method, resulting in ultra-wide chiral flat-band cascades in magic-angle twisted bilayer gratings. Our work not only provides a platform for designing photonic applications with tunable localization but also explores a new regime of physics unattainable in conventional solid-state based moir\'e systems.