mechanical design teams

Abstract: Resonance-induced excessive vibrations can degrade performance, reduce reliability, and shorten the service life of engineering structures. To reduce the risk of resonance, structural natural frequencies are generally engineered to be shifted away from excitation frequencies. To achieve these frequency shifts, topology optimization provides a systematic approach to tailor structural stiffness and mass as an effective inverse design approach. Multi-material topology optimization exploits the high-dimensional design space of spatially varying material constituents by simultaneously optimizing material selection and spatial distribution over the design domain, offering great flexibility in controlling natural frequencies. This study proposes a multi-material topology optimization that attenuates excessive structural dynamic vibrations in free-vibration scenarios via a novel multivariate weight-based interpolation method. Additionally, to address non-smoothness due to mode switching amid optimization, we employ a bound formulation with an auxiliary scalar design variable to replace the max-min eigenvalue objective with constraints on individual eigenvalues. Furthermore, we study and compare three optimization formulations for multi-material design to attenuate vibrations, including maximizing fundamental eigenfrequency, maximizing the gap between adjacent eigenfrequencies, and excluding frequencies from targeted frequency bands, which are smoothly approximated by a proposed rational polynomial formulation. Numerical examples are presented to demonstrate the effectiveness and applicability of our proposed method.

Abstract: We develop an uncertainty-aware, operator-learning-based surrogate for tendon-driven continuum robots (TDCRs) that generalizes across robot design and actuation while predicting the complete equilibrium configuration. Our central idea is a nonstationary Gaussian-process (GP) kernel whose metric is learned by a shallow neural network from mechanics-aware design coordinates. The network learns how similarity changes across design space, while the resulting kernel defines the design-to-pose operator, its posterior uncertainty, and a criterion for sequential simulator acquisition. We represent backbone position and rotational strain with spatial kernels and reconstruct orientation directly on SO(3), preserving valid material frames and tendon geometry. We use ASkotch with Nystrom preconditioning for scalable kernel operator solves and a separate Nystrom approximation for posterior covariance. Experiments show that kernel-coverage acquisition reduces mean trajectory error by approximately 15% relative to IID sampling, while posterior variance increases for increasingly unsupported designs. Compared with prior neural-operator TDCR models, the method is 30-50% more accurate using approximately 5x fewer training designs while additionally providing posterior uncertainty estimates.

Abstract: Topology optimization has found significant utility in additive manufacturing, but the resulting geometries are often difficult to realize using subtractive methods. The complex, curved surfaces of optimized designs typically require time-consuming point milling operations. In contrast, geometries composed of developable surfaces are well suited to flank milling, enabling substantial improvements in machining efficiency and surface quality. However, globally minimizing Gaussian curvature leads to overly simplistic designs. We address this challenge with a novel method that represents geometry using three implicit neural fields, optimized to produce machinable components. The resulting designs consist of regions of developable surfaces separated by seamlines where curvature is concentrated. Seamlines are efficiently computed as intersections of the implicit fields, while the geometry emerges through their product. By constraining surfaces to align with the cutter's normal or tangential direction, our approach further accommodates practical constraints of 3-axis machining. We demonstrate concurrent optimization of topology and Gaussian curvature, enabling control over seamline feature scale. Compared to methods that enforce subtractive machinability without considering milling efficiency, our approach consistently reduces machining time while maintaining competitive structural performance.

Abstract: Deep learning has emerged as an efficient alternative for predicting high-performance material distributions in topology optimization. Existing methods struggle to accurately capture load-transfer information, limiting out-of-distribution generalization, while their model architectures often incur high computational costs. To address these challenges, this paper proposes TopoMamba, a topology prediction framework incorporating a load-support relation-guided multi-directional state-space model. Coupling physical fields with load-support relations enables more effective modeling of mechanical dependencies. A load-support relation-guided spatially adaptive fusion mechanism dynamically adjusts multi-directional scan features according to spatial conditions. Mamba is coupled with the solid isotropic material with penalty method to enhance structural mechanical performance while maintaining computational efficiency. Results on two-dimensional topology optimization benchmarks demonstrate that TopoMamba achieves superior topology prediction accuracy, out-of-distribution generalization, and computational efficiency over state-of-the-art models. The proposed load-support physics-guided framework enables efficient optimization of more complex structural systems.

Abstract: Lattice metamaterials support lightweight, multifunctional structures, while additive manufacturing (AM) enables complex geometries. Yet multiphysics lattice design faces two challenges: efficiently constructing well-covered multi-objective Pareto fronts under limited budgets, and satisfying manufacturing constraints such as overhangs, enclosed cavities, and restricted powder-removal channels. We propose a manufacturing-constraint-driven method for lattice optimization and Pareto-front construction. Differentiable manufacturing constraints are embedded in inverse-homogenization topology optimization, enabling joint optimization of physical performance and manufacturability. A progressive Pareto-front mechanism uses a density-generation network to learn latent representations of high-quality lattices, interpolates neighboring nondominated representations, and decodes them into initial density fields for subsequent optimization. Newly found nondominated solutions update the network and sample set, progressively expanding the manufacturable set. On 3D periodic unit cells, with 1000 optimization runs, network initialization achieves a 92.60% success rate and 916 manufacturable samples, versus 78.30% and 776 for random initialization. Its Pareto front reaches a hypervolume of 0.0787, compared with 0.0675 for random initialization. The results show that the method efficiently constructs broadly covered manufacturable Pareto fronts for multiple physical properties.

Abstract: Joint-Embedding Predictive Architectures (JEPAs) provide a framework for learning compact representations without directly reconstructing high-dimensional observations. However, in parameterized physical systems, learned representations can entangle geometry with operating conditions and task-specific physical responses, limiting their reuse across prediction tasks. We introduce D-JEPA (Design-recoverable JEPA), a geometry-centric JEPA that computes a compact representation from geometry alone and reuses it across operating conditions and physical response spaces through lightweight physics-specific decoders. An explicit design-recoverability objective encourages the geometry latent to preserve information about the underlying design variables, enabling the representation to support design analysis and optimization. We further identify a case-level collapse failure mode in which target representations become nearly invariant across distinct geometries despite low reconstruction error, and mitigate it using case-level variation constraints and auxiliary target reconstruction. Across four 3D aerodynamic, hydrodynamic, and structural benchmarks, D-JEPA maintains or improves full-field prediction accuracy while achieving near-perfect linear recoverability of design parameters. The frozen geometry representation can be reused at held-out operating conditions and transferred to a structural response task with fewer trainable parameters. Finally, the representation supports differentiable design optimization, with designs validated using high-fidelity CFD, preserving the predicted ranking of candidate designs. These results demonstrate that separating a reusable geometry representation from physics-specific prediction provides a practical representation for scientific surrogate modeling and design.

Abstract: This paper presents novel approaches to tackle two key challenges in topology optimization problems with buckling constraints: determining how many eigenvalues to aggregate and identifying the eigenvalue modality at the optimal design. We demonstrate the mathematical inconsistencies that arise when choosing an arbitrary fixed number of eigenvalues for aggregation. Specifically, if the multiplicity of the critical eigenvalues is smaller than the chosen subset size, coalescence with higher-order eigenvalues can occur. Neglecting these during aggregation causes incorrect sensitivities, while simply increasing the preselected eigenvalue count unnecessarily raises computational costs. To resolve this issue, we propose an approach that dynamically determines the exact number of eigenvalues required at each optimization iteration. The proposed approach reduces computation time significantly while maintaining competitive performance relative to the conventional method across the numerical experiments presented. Additionally, accurately predicting modality at the optimal point is crucial for understanding the buckled mode shapes of optimized designs. A new optimization formulation is proposed using the difference between eigenvalues to capture the true eigenvalue modality. This formulation is first validated on a classical 1D clamped column, successfully predicting both the bimodal solution and the optimal eigenvectors. The approach demonstrates that the optimal solutions for the wall reinforcement and shear-loaded hinged plate problems for the given set of parameters are trimodal and tetramodal, respectively.

Abstract: Vibroacoustic analysis often requires coupling structural and acoustic solvers based on different numerical formulations and discretizations, making monolithic implementations intrusive and limiting software modularity and reuse. This work presents a partitioned co-simulation framework for exterior vibroacoustic analysis that couples an Isogeometric boundary representation analysis (IBRA) structural solver with an isogeometric boundary element method (IGA-BEM) acoustic solver. The methodology operates directly on the computer-aided design (CAD) boundary representation, preserving the exact geometry throughout the analysis and supporting both weak and strong coupling between non-conforming discretizations. A key contribution is the extension of the Aitken dynamic relaxation and Interface Quasi-Newton with Inverse Least-Squares (IQN-ILS) convergence accelerators to complex-valued interface quantities, allowing the coupling iterations to account directly for both amplitude and phase information. The approach is validated using one-way and two-way coupled vibroacoustic benchmark problems involving thin-shell structures and exterior acoustic domains. The results show excellent agreement with monolithic reference solutions, while the proposed complex-valued convergence accelerators improve the robustness and convergence behavior of the strongly coupled solution procedure without compromising solution accuracy. These results demonstrate that the proposed approach provides an accurate, robust, and modular approach for CAD-integrated frequency-domain vibroacoustic analysis.

Abstract: Density-based topology optimization is typically structured as a nested sequence of material updates, structural analyses, and sensitivity assessments. While neural density parameterization and dual-field physics-informed approaches provide data-free alternatives, most existing methods represent density and displacement as coordinate fields and make limited use of the discrete relationships inherent in the finite element mesh. The present study introduces HGTO, a unified graph-based formulation that extends complete neural topology optimization from coordinate space to finite-element graph space. Element densities are parameterized on the element graph derived from the mesh, and the structural state is determined on the corresponding node--element hypergraph. Finite element kinematics, numerical quadrature, constitutive response, and force assembly remain explicitly defined operations within the differentiable computation. The material field and equilibrium state are therefore coupled through a common finite-element incidence structure. Numerical studies show compliance comparable to conventional density-based optimization at substantially lower computational cost than a representative coordinate-based dual-field neural method. The same coupled formulation accommodates high-resolution and irregular meshes, three-dimensional structures, finite deformation, and elastoplastic response.

Abstract: Early thermal-mechanical lattice requirements are knowledge-intensive and often jointly unsatisfiable: an engineer asks for a cell that is light, stiff, laterally conducting and cheap, and no cell in the library satisfies it. A design system should say so, and say which requirement to loosen and by how much, rather than return the nearest row. A generative model can return a candidate even when the library holds none. This work applies established conflict diagnosis to a catalogue of homogenised properties. Search over 1,397 homogenised unit cells and 19 base materials (26,543 combinations) returns a catalogue row that a second solver can rebuild, or, for an empty feasible set of at most eight constraints, inclusion-minimal unsatisfiable subsets (MUS) and the slack of a repair, not a neighbour. One registry declaration generates the prompt and the evaluator, so undeclared parsed keys cannot reach search. On a frozen suite of 64 typed queries, retrieve-or-refuse matches min-repair on every feasible query (48/48) and refuses every empty one (16/16) with MUS and slack. Constraint-ignoring nearest-neighbour and penalty search violate stated cost or density limits. On 216 empty queries, repairs printed at three significant figures and rounded outward stay feasible in every case (216/216). When density and cost must be kept, a list of minimum-cardinality repairs keeps them on 209 of 211 queries; a protection-first repair keeps them on all 211, the same as full diagnosis. A 308-request parse benchmark is a template-text check, not unconstrained engineer prose.

Abstract: Closed kinematic chains complicate modular modeling by coupling active and passive coordinates through nonlinear closure constraints. This paper presents a Path-Assembled Closure Differential Mapping (PACDM) framework for modular closure resolution and kinematic reduction. Each closure element compares two ordered transformation paths with common endpoints, with their mismatch expressed through the logarithm on SE(3) and the corresponding Jacobian assembled from local transformation derivatives. Multi-path modules are constructed from a minimal set of pairwise closure elements, while rank-revealing analysis selects locally independent scalar constraints. A defect homotopy recovers closure-consistent passive coordinates from approximate estimates along a feasible and regular continuation path. At regular configurations, implicit differentiation yields the local active-to-passive differential mapping, which is subsequently used in a predictor-corrector continuation procedure for prescribed motion. The framework is evaluated on a seven-degree-of-freedom heavy-duty manipulator containing two-path and three-path closed-chain modules. Comparison with Simscape Multibody yields trajectory root-mean-square errors below 8.5 x 10^-10 rad, while predictor-corrector continuation is approximately 45.8 times faster than applying defect homotopy at every trajectory sample.

Abstract: Turbomachinery design optimization involves expensive black-box problems. Sample-efficient multi-fidelity optimization (MFO) offers an efficient solution. By utilizing multi-fidelity surrogates (MFS), the MFO algorithm can use fewer high-fidelity samples aided by low-fidelity samples to establish an accurate surrogate model. However, when MFS is used in sequential sampling optimization, it has been observed that the final optimal solution obtained by single-fidelity optimization (SFO) is better than that of MFO, even though MFO performs better at the early stages. This can be attributed to the assumption of an even and nested distribution of samples, which is incorrect when using a sequential adding strategy. To address these issues, we propose a novel algorithm called multi-single-fidelity optimization (MSFO) to overcome the limitations of the conventional MFO procedures. In the surrogate establishment of MSFO, we use the density-based spatial clustering of applications with noise (DBSCAN) method to detect local areas where low-fidelity samples are no longer effective. A combination of both global MFS and local single-fidelity surrogate model, built using high-fidelity samples alone, is used to establish an ensemble, which improves the anti-interference ability of the algorithm against misleading low-fidelity data. The effectiveness of the MSFO algorithm is verified first on numerical benchmark functions. Then, the algorithm is used to optimize the aerodynamic profile of a turbine and the film cooling layout design of a turbine endwall. Here, high-fidelity sample sources are obtained from fine-mesh CFD simulations, whereas low-fidelity sample sources are obtained from the same simulations run on a coarser mesh. The results demonstrate that our MSFO algorithm performs significantly better than the conventional SFO and MFO processes, with a higher level of robustness.

Abstract: This paper proposes a topology optimization method for reducing the residual stress arising in the building process of metal additive manufacturing. First, a layer-by-layer process analysis model based on an elastoplastic inherent strain method is introduced. In this model, the incremental displacement is solved anew at each layer step, and the stress history is explicitly incorporated into the constitutive equation as the stress accumulated up to the previous step, which guarantees the stress continuity across layer interfaces without introducing activation strains. Next, the design sensitivity of this analysis model is derived based on the adjoint method. Taking the pair of the stress and the equivalent plastic strain as the state variables reduces the dependency between layer steps to a one-step recurrence, and the adjoint fields are constructed as a layer-by-layer reverse sweep that reuses the coefficient tensors obtained in the forward analysis. Consequently, the cost of the sensitivity analysis scales linearly with the number of layers and remains of the same order as that of the forward analysis. An optimization problem is then formulated based on the density method to minimize the P-norm of the residual stress at the completion of the building process under the volume and final-use compliance constraints, and the derived sensitivities are verified by comparison with central finite differences. Finally, the proposed method is demonstrated through two- and three-dimensional examples of residual stress minimization under a compliance constraint. The results clarify that, under the elastoplastic analysis, the maximum residual stress is bounded by the yield surface, and the optimization therefore reduces the extent of the yielded and plastic strain accumulating regions rather than the peak stress value.