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Shape optimization

Shape optimization is a branch of applied mathematics and engineering that focuses on finding the geometric configuration of a domain or structure which minimizes or maximizes a given objective functional, such as compliance, drag, or energy consumption, subject to constraints like volume or boundary conditions, without altering the domain's topology.^[1] This process typically involves formulating the problem as \inf \{ J(\Omega) \mid \Omega \in \mathcal{S}_{ad} \}, where J(\Omega) is the shape functional and \mathcal{S}_{ad} denotes the class of admissible shapes.^[2] Unlike topology optimization, which allows changes in connectivity such as adding or removing holes, shape optimization deforms the boundary of an existing domain to achieve optimality.^[3] The field traces its origins to early 20th-century work on boundary variations, notably Jacques Hadamard's method for evaluating sensitivities of domain functionals to small perturbations of the boundary.^[4] Significant advancements occurred in the 1980s with the integration of homogenization techniques and finite element methods, enabling practical numerical implementations.^[4] Modern approaches rely on shape derivatives to compute sensitivities, often using adjoint methods for efficiency in high-dimensional problems, and discretization techniques such as level-set methods or parametric representations (e.g., B-splines) to handle complex geometries.^[5]^[6] Key applications span multiple disciplines, including structural mechanics for minimizing compliance in load-bearing components, aerodynamics for reducing drag on airfoils and vehicle hulls, and fluid dynamics for optimizing flow around obstacles.^[4] In aerospace engineering, shape optimization has been applied to complex configurations like multi-element airfoils using computational fluid dynamics (CFD) and sensitivity analysis to improve performance metrics.^[5] Recent developments incorporate machine learning surrogates and data-driven methods to accelerate simulations, particularly for multidisciplinary problems involving thermal or electromagnetic effects.^[6] Challenges persist in ensuring existence and regularity of solutions, as well as handling non-smooth domains and manufacturing constraints.^[1]

Fundamentals

Definition and Motivation

Shape optimization is the process of determining the optimal geometry of a domain or object to extremize a given performance criterion, such as minimizing drag force in fluid flow or maximizing structural stiffness under load, while adhering to specified constraints like volume limits or manufacturing feasibility. This approach treats the shape as the primary design variable, allowing systematic variations to achieve superior outcomes compared to traditional trial-and-error methods. The core idea stems from the calculus of variations, where small perturbations to the boundary enable the computation of sensitivities that guide iterative improvements.^[4]^[7] The field emerged prominently in the 1970s and 1980s, building on foundational concepts from the calculus of variations—dating back to early 20th-century works like Hadamard's boundary variation method—and the rapid advancement of finite element methods for numerical simulation. These developments were particularly motivated by demands in aerospace and automotive industries for enhanced efficiency amid rising energy costs and performance requirements; for instance, in aerospace, reducing structural mass by even 1 pound could save approximately $20,000 per spacecraft flight, while in automotive design, a 10% mass reduction typically improves fuel economy by about 7%. Seminal contributions during this period, such as Schmit's 1960 paper on numerical search methods and subsequent optimality criteria approaches in the 1970s, integrated finite element analysis with optimization algorithms to handle complex engineering problems.^[8]^[4] Key benefits of shape optimization include substantial improvements in overall performance, such as lower energy consumption and higher load-bearing capacity, alongside reductions in material usage and enhancements in safety margins, all without modifying the underlying physical laws governing the system. These advantages arise from the ability to explore a vast design space efficiently, often yielding counterintuitive geometries that outperform heuristic designs. The basic workflow entails defining a shape functional J(\Omega), where \Omega represents the domain, solving associated partial differential equations to evaluate performance, computing shape sensitivities via domain perturbation techniques, and iteratively deforming the boundary to minimize or maximize J until convergence. Detailed mathematical formulations of these steps are addressed in subsequent sections.^[8]^[4]

Mathematical Formulation

Shape optimization problems are generally formulated as the minimization of a shape functional J(\Omega) over a class of admissible domains \Omega \subset D, where D is a fixed hold-all open set in \mathbb{R}^d.^[9] The functional often takes the form

J(\Omega) = \int_{\Omega} f(x, u(x)) \, dx,

where u is the state variable solving a partial differential equation (PDE) constraint, such as the Poisson equation -\Delta u = g in \Omega with homogeneous Dirichlet boundary conditions u = 0 on \partial \Omega.^[10] This PDE-constrained setup arises in applications where the objective depends on both the geometry and the physical response governed by the PDE.^[11] The mathematical analysis of such problems relies on shape calculus, which distinguishes between Eulerian and Lagrangian descriptions for perturbations of the domain. In the Eulerian framework, the coordinate system is fixed, and the domain is deformed via a velocity field V: D \to \mathbb{R}^d, leading to the Eulerian semi-derivative dJ(\Omega; V) defined as the directional derivative along the flow F_t(x) = x + t V(x).^[12] The Lagrangian description, in contrast, follows material points and employs material (Lagrangian) derivatives of functions defined on the evolving domain, which relate to Eulerian derivatives via the chain rule involving the normal component of V on the boundary.^[12] For efficient computation of sensitivities in PDE-constrained settings, adjoint methods are employed to derive the shape derivative. The adjoint state p solves an auxiliary PDE derived from the Lagrangian of the optimization problem, enabling the expression of the Eulerian derivative as a boundary integral

dJ(\Omega; V) = \int_{\partial \Omega} G (V \cdot n) \, ds,

where n is the outward unit normal to \partial \Omega, and G is a scalar function depending on the state u, adjoint p, and problem data.^[10] This form avoids direct dependence on volume integrals and facilitates gradient-based algorithms.^[9] Constraints are integral to the formulation, ensuring physical and geometric feasibility. Volume constraints, such as |\Omega| \leq V_{\max}, are commonly imposed and handled via Lagrange multipliers in the augmented functional or through penalty terms.^[11] Inequality constraints on shape perturbations restrict the velocity field V to admissible spaces, such as H^1_0(D, \mathbb{R}^d), to maintain domain regularity and prevent intersections.^[10] The existence of shape derivatives is underpinned by the Hadamard structure theorem, which asserts that for sufficiently smooth domains \Omega of class C^k (k \geq 1) and perturbations generated by velocity fields in C^{k-1,\infty}(D, \mathbb{R}^d), the shape derivative dJ(\Omega; V) admits the boundary-supported form \int_{\partial \Omega} G(V \cdot n) \, ds, independent of the extension of V inside \Omega.^[9] This theorem ensures well-posedness of the differentiability under smooth perturbations and forms the foundation for theoretical analysis.^[11]

Applications

Engineering Design

In engineering design, shape optimization plays a pivotal role in enhancing aerodynamic performance by minimizing drag on airfoils and vehicle bodies. For instance, NASA's PRANDTL-D wing design achieves a 12% drag reduction through integrated bending moments and lift optimization, enabling lighter, more efficient aircraft structures that lower fuel consumption.^[13] Similarly, multipoint aerodynamic shape optimization of the NASA Common Research Model wing results in up to 7.5% drag reduction relative to baseline designs, improving off-design performance and overall fuel efficiency.^[14] Structural optimization leverages shape adjustments to maximize the stiffness-to-weight ratio in components like aircraft frames and bridges, often inspired by finite element models. For bridges, size and shape optimization of long portal structures significantly reduces overall weight without complicating construction, enhancing material efficiency and load-bearing capacity.^[15] Shape optimization also addresses acoustic and thermal challenges in engineering. In acoustic applications, multi-chamber cross-flow mufflers optimized for shape parameters achieve superior broadband noise reduction compared to simpler configurations, with increased chambers enhancing attenuation across frequency ranges.^[16] For thermal management, pin-fin heat sinks subjected to shape optimization via genetic algorithms improve the coefficient of performance by 55%, balancing thermal resistance and pressure drop for better cooling efficiency in electronic systems.^[17] A notable case study involves the optimization of wind turbine blades, where aerodynamic shape adjustments through blade element momentum theory and genetic algorithms increase annual energy output by 8.5% via iterative reshaping to enhance lift and reduce drag.^[18] This approach demonstrates how targeted shape modifications can boost power generation in renewable energy systems. Finally, shape optimization integrates seamlessly with computer-aided design (CAD) workflows and advanced manufacturing processes like 3D printing, allowing optimized geometries to be directly exported for fabrication. Tools such as Autodesk's shape optimization module enable iterative design refinement within CAD environments, facilitating lightweight structures that are printable with minimal material waste and high fidelity to performance goals.^[19] Recent advances include shape optimization for 3D concrete printing, streamlining designs for automated construction and integration with CAD/CAM workflows as of 2025.^[20]

Biomedical and Material Sciences

In biomedical applications, shape optimization plays a crucial role in designing stents to minimize disruptions in blood flow and reduce the risk of thrombosis. By streamlining strut geometries, such as transitioning from rectangular to circular arc shapes and reducing strut thickness to 50-100 µm, computational simulations demonstrate a significant decrease in peri-strut recirculation zones and low wall shear stress areas, which promotes endothelialization and lowers thrombosis potential. For instance, optimized circular arc struts achieved 100% endothelial coverage under pulsatile flow conditions, compared to 12-26% unendothelialized areas with thicker rectangular struts, thereby mitigating flow separation and associated clotting risks.^[21] In material sciences, shape optimization of microstructures, including crystal lattice configurations in composites, enhances mechanical strength and functional properties like vibration damping in metamaterials. Periodic microstructure designs, optimized via homogenization methods, tailor unit cell geometries to maximize stiffness under given volume constraints, achieving superior strength-to-weight ratios in composite materials. For example, in lattice-based metamaterials, optimizing cell shapes for damping introduces bandgaps that attenuate vibrations, with data-driven approaches enabling elastically isotropic structures that improve energy absorption by balancing density and dissipation properties.^[22] Pharmaceutical applications leverage shape optimization for drug delivery systems, such as capsules or particles, to maximize diffusion rates and control release profiles. Varying the geometry of degradable implants, including aspect ratios and surface curvature, influences unidirectional drug elution, with elongated or anisotropic shapes extending release durations to 5-7 days while enhancing mass transfer efficiency through steeper concentration gradients. These optimizations ensure sustained therapeutic levels by tailoring diffusion pathways, as non-spherical particles exhibit higher loading efficiencies and more predictable release kinetics compared to spherical counterparts.^[23]^[24] Recent developments in biomedical shape optimization include adjoint-assisted designs for idealized arterial bypass grafts under uncertainties, improving hemodynamic performance as of 2025.^[25] Ethical considerations in shape optimization for biomedical and material applications emphasize balancing performance gains with biocompatibility standards, such as those outlined in FDA guidelines. Optimized designs must undergo rigorous testing under ISO 10993 to ensure no adverse tissue reactions, prioritizing patient safety over idealized geometries that might compromise long-term implant integration or introduce unforeseen toxicities.^[26]

Methods

Shape Representation Techniques

Shape representation techniques are crucial in shape optimization as they define how geometric domains are parameterized and evolved during the iterative process, enabling efficient computation of design sensitivities and updates. These methods must balance flexibility in capturing complex geometries with computational tractability, often representing the shape Ω ⊂ D, where D is a fixed holding domain, through implicit or explicit descriptions. Common approaches include implicit representations like level sets and phase fields, explicit boundary parametrizations, and perturbation-based velocity fields, each suited to different aspects of shape evolution and topology handling. Level-set methods represent the shape Ω implicitly as the sublevel set {x ∈ D | φ(x) ≤ 0}, where φ: D → ℝ is a smooth level-set function, typically initialized as a signed distance function to the boundary ∂Ω. The evolution of the shape under a normal velocity V is governed by the Hamilton-Jacobi equation:

\frac{\partial \phi}{\partial t} + V |\nabla \phi| = 0,

which propagates the interface while maintaining smoothness through reinitialization techniques. This framework, originally developed for front propagation, has been adapted for shape optimization to handle boundary variations and topology changes naturally without explicit tracking. In structural optimization contexts, the level-set function is updated using shape sensitivities derived from adjoint methods, allowing for gradient-based descent on objective functionals. Boundary parametrization techniques explicitly describe the boundary ∂Ω using parametric curves or surfaces, such as B-splines or non-uniform rational B-splines (NURBS), where control points serve as design variables. For a 2D curve, a B-spline of degree p is defined as ∑{i=0}^n N{i,p}(u) P_i, with knot vector and control points P_i parameterizing the geometry; NURBS extend this by incorporating weights for conic sections and rational approximations. These methods integrate seamlessly with computer-aided design (CAD) systems and finite element analysis, particularly in isogeometric approaches where the same basis functions discretize both geometry and solution fields, ensuring exact representation of complex shapes. Velocity field approaches perturb the shape through diffeomorphisms generated by time-dependent vector fields V ∈ H^1(D)^d, where the deformation map T_t satisfies ∂T_t/∂t = V(T_t) with T_0 = Id, transforming Ω to T_t(Ω). This formalism, rooted in shape calculus, allows for the computation of material derivatives and shape gradients via the velocity method, ensuring perturbations remain volume-preserving or satisfy boundary conditions. Such representations are particularly useful for theoretical analysis and numerical schemes requiring high regularity, as the Sobolev space H^1 ensures the diffeomorphisms are sufficiently smooth. To handle topology changes like merging or splitting of domains, phase-field models introduce a diffuse interface approximation using an order parameter ψ ∈ [0,1], where ψ ≈ 1 in Ω and ψ ≈ 0 outside, regularized by a Ginzburg-Landau energy ∫_D (ε/2 |∇ψ|^2 + (1/ε) W(ψ)) dx with double-well potential W and small ε > 0 controlling the interface width. The evolution follows a Allen-Cahn equation ∂ψ/∂t = -δE/δψ, coupled with the optimization objective, enabling smooth transitions without explicit topology tracking. This approach contrasts with sharp-interface methods by inherently allowing nucleation and bifurcation events during optimization. Level-set methods offer superior flexibility for topology optimization due to their implicit nature, avoiding parametrization singularities, but they require frequent reinitialization and can suffer from numerical diffusion over iterations. In contrast, boundary parametrization provides precise control over smoothness and is computationally efficient for smooth shapes without topology changes, though it struggles with discontinuities or high-dimensional parametrizations leading to the curse of dimensionality. Velocity field methods excel in rigorous sensitivity analysis but demand careful discretization to maintain diffeomorphism properties, while phase-field models promote stability in topology handling at the cost of increased computational expense from diffuse interfaces.

Gradient-Based Optimization

Gradient-based optimization methods in shape optimization utilize the shape derivative, or gradient, to iteratively improve the domain Ω that minimizes an objective functional J(Ω) subject to partial differential equation (PDE) constraints. These approaches exploit the differentiability of J with respect to perturbations of the boundary ∂Ω, enabling local search strategies that converge to stationary points under suitable regularity assumptions. Central to this framework is the computation of the gradient via boundary integrals, which informs deformation fields for shape updates.^[9] A key tool for deriving the shape gradient is the Hadamard formula, which expresses the directional derivative dJ(V) of the functional J(Ω) in the direction of a velocity field V as a boundary integral over ∂Ω. Specifically, for problems formulated using a Lagrangian L, the formula yields

dJ(V) = \int_{\partial \Omega} \frac{\partial L}{\partial n} \, V \cdot n \, ds,

where n denotes the outward unit normal to ∂Ω. This representation, originally developed by Hadamard for elastic problems and extended to general PDE-constrained functionals, reduces the volume integral of the material derivative to a surface term, facilitating efficient numerical evaluation. The formula holds for sufficiently smooth domains and velocity fields supported near the boundary, assuming the Eulerian derivative exists.^[9]^[27] To compute the gradient efficiently in PDE-constrained settings, where direct differentiation would require solving multiple forward problems, the adjoint-state method is employed. This involves introducing an adjoint variable p that satisfies a PDE derived from the Lagrangian, such as the Poisson equation -Δp = -∂f/∂u in Ω with homogeneous Dirichlet boundary conditions p = 0 on ∂Ω, where f represents the objective dependence on the state u. The solution p then allows the shape gradient to be assembled as G = ∂L/∂u p + boundary terms, avoiding repeated state solves and scaling linearly with the number of optimization iterations rather than design variables. This technique, formalized in the context of shape sensitivity analysis, ensures that gradient evaluation costs match that of a single forward-adjoint pair.^[28]^[29] With the gradient ∇J available, iterative algorithms like steepest descent update the shape via the flow Ω_{k+1} = (I + τ V_k) Ω_k, where V_k = -∇J(Ω_k) is the descent direction and τ > 0 is a step size chosen to ensure descent, often via line search. This deforms the domain along the negative gradient flow, preserving topology if V is tangential or extending it otherwise. Such updates are particularly effective for smooth, convex problems, where the method guarantees decrease in J at each step.^[30] Under convexity assumptions on J and smoothness of the constraints, steepest descent exhibits a convergence rate of O(1/k) for the functional values after k iterations, meaning the error decreases inversely with the iteration count. This rate holds for strongly convex quadratics and extends to shape problems with Lipschitz gradients, though practical performance may vary with ill-conditioning from eigenvalue spreads in the Hessian. Global convergence to stationary points is established in spaces such as W^{1,∞} for the velocity fields, provided Armijo-type line searches are used.^[31]^[32] These gradient-based techniques are integrated into software tools for practical PDE-constrained shape optimization. For instance, FreeFem++ supports adjoint-based gradient computation and steepest descent via its finite element solver, enabling implementations for fluid-structure interactions and elasticity problems. Similarly, COMSOL Multiphysics incorporates the adjoint method in its Optimization Module for shape deformation, allowing users to optimize boundaries in multiphysics simulations like electromagnetics or heat transfer.^[33]^[34]

Non-Gradient and Hybrid Approaches

Non-gradient approaches in shape optimization encompass derivative-free techniques that are particularly valuable for problems where computing gradients is infeasible or unreliable, such as those involving non-differentiable objectives or complex multiphysics interactions. These methods often employ stochastic search strategies to explore the design space globally, avoiding local minima that can trap gradient-based optimizers.^[35] Evolutionary algorithms, such as genetic algorithms (GAs), represent a prominent class of non-gradient methods applied to shape optimization. In GAs, shapes are parameterized by sets of variables encoded as chromosomes within a population of candidate solutions. The algorithm evolves these populations over generations through selection, crossover, and mutation operators: crossover combines features from parent shapes by averaging corresponding parameters, while mutation introduces random perturbations to promote diversity and escape local optima. This process is well-suited for multimodal landscapes in aerodynamic shape design, where multiple local extrema arise due to nonlinear flow physics, enabling the discovery of Pareto-optimal trade-offs in multi-objective problems like maximizing lift-to-drag ratios while constraining volume. For instance, in transonic wing optimization, GAs have demonstrated reliable convergence to diverse solutions without requiring gradient information.^[35] Level-set methods without adjoint computations offer another non-gradient avenue for evolving shapes, particularly in structural optimization. These approaches represent the domain boundary implicitly via a level-set function and update it using heuristic velocity fields that drive the front propagation, bypassing the need for sensitivity analysis through adjoints. For self-adjoint problems like compliance minimization in linear elasticity, the velocity can be directly derived from the shape functional's variation, often smoothed via PDE extensions to ensure regularity. Heuristic velocities, such as those incorporating mean curvature flow, are employed to regularize the boundary and penalize perimeter growth, promoting smoother topologies during evolution. This evolution follows a Hamilton-Jacobi equation solved on a fixed mesh, facilitating topology changes without remeshing. Such methods have been effectively used for minimizing structural compliance under volume constraints.^[36] Particle swarm optimization (PSO) treats shape parameters, such as control points of spline-based representations, as particles in a swarm that collectively search the design space. Each particle updates its position and velocity based on cognitive components (personal best positions) and social components (global or neighborhood bests), balancing exploration and exploitation through adjustable parameters like inertia weight and acceleration constants. In structural shape optimization, PSO has been applied to truss and frame designs with size and shape constraints, outperforming genetic algorithms in convergence speed while achieving comparable optima to gradient methods. The introduction of elite particles and velocity operators further enhances its efficiency for constrained problems.^[37] Hybrid approaches integrate non-gradient techniques with gradient information or machine learning surrogates to leverage the strengths of both, particularly for expensive simulations in shape optimization. For example, gradient-enhanced Kriging surrogates combine local gradient data from adjoint solvers with global interpolation models to approximate the objective functional J(Ω), allowing fewer full PDE evaluations during optimization. These hybrids have reduced computational effort in aerodynamic airfoil design, for example, achieving up to 50% drag reduction compared to baseline designs with surrogate-assisted iterations.^[38] In multi-objective settings, coupling deep neural network surrogates with evolutionary algorithms like NSGA-III further accelerates convergence by approximating flow solutions, cutting overall PDE solve requirements significantly compared to direct evaluations.^[38] These non-gradient and hybrid methods are especially effective for non-smooth or noisy objectives prevalent in multiphysics simulations, where gradient approximations fail due to chaotic behaviors like flow unsteadiness in large eddy simulations. Unlike gradient-based methods focused on local refinement, they enable robust global search in such environments, as demonstrated by derivative-free optimizers like MADS achieving substantial lift enhancements in low-Reynolds airfoil designs amid simulation noise.^[39]

Challenges and Advances

Computational Challenges

One major computational challenge in shape optimization arises from mesh deformation during iterative shape updates, where finite element meshes can suffer from distortion, leading to degraded element quality and solver instability. This distortion often necessitates remeshing techniques, such as the elastic analogy method, which treats the mesh as an elastic body to propagate boundary deformations smoothly into the interior while minimizing tangling and inversion.^[40] Such approaches, however, introduce additional computational overhead.^[41] High-dimensional design spaces exacerbate the curse of dimensionality in shape optimization, where problems with 100 or more parameters—such as control points in spline representations—result in exponentially growing search spaces and ill-posed formulations that hinder convergence.^[42] This phenomenon amplifies sensitivity to initial conditions and noise, making global exploration infeasible without dimensionality reduction strategies, though even reduced spaces often retain hundreds of effective dimensions in engineering applications like aerodynamic design.^[43] The non-convex nature of the objective functional J(\Omega) in shape optimization leads to multiple local minima and equilibria, complicating the identification of globally optimal shapes and often trapping gradient-based algorithms in suboptimal solutions.^[44] To mitigate this, regularization techniques such as Tikhonov terms, typically of the form \alpha \|V\|^2 where V represents the shape velocity field and \alpha > 0 is a tuning parameter, are employed to penalize excessive deformations and promote smoother, more stable optima.^[45] Scalability remains a significant hurdle, particularly with adjoint-based methods, where the computational cost of solving the adjoint equations scales poorly with grid resolution; in 3D problems, direct solvers can exhibit O(n^3) complexity relative to the number of degrees of freedom n, limiting practical applications to coarse meshes or requiring expensive parallelization.^[46] Even though adjoints provide gradients independent of design variable count, the repeated forward and adjoint solves per iteration can demand substantial computational resources for high-fidelity simulations.^[47] Finally, validation of optimized shapes poses challenges due to the need for experimental verification, as computational simulations frequently overlook real-world manufacturing tolerances, such as surface roughness or dimensional variations in additive processes, which can degrade predicted performance.^[48] Bridging this gap requires integrated testing, yet discrepancies between simulated and fabricated outcomes often necessitate iterative redesigns.^[49]

Recent Developments

Since the 2020s, machine learning has significantly advanced shape optimization by integrating neural networks as surrogate models for the objective functional J(Ω), particularly through physics-informed neural networks (PINNs) that embed partial differential equations (PDEs) directly into the loss function. This approach enables rapid evaluation of complex physics, often accelerating PDE solvers by 3-4 orders of magnitude compared to traditional finite element methods, with errors below 1% in benchmark cases like electromagnetic iron core designs. For instance, in airfoil optimization, PINNs combined with convolutional neural networks and deep reinforcement learning have achieved lift-drag ratio improvements of up to 1.48 times at Reynolds numbers around 6×10^6, evaluating designs in milliseconds rather than hours. The post-2020 surge in PINN applications has been driven by their ability to handle high-dimensional design spaces without extensive mesh generation, as demonstrated in evolutionary optimization frameworks that enhance generalization for inverse problems.^[50]^[51]^[52] Multiphysics coupling has progressed to simultaneous optimization of fluid-structure interactions (FSI), particularly in flexible structures. In airfoil applications, soft finite element methods driven by multiphysics frameworks have optimized 3D shapes for aerodynamic loads, achieving improvements in compliance. These advances enable real-time FSI simulations for applications like aeroelastic wings, bridging isolated discipline optimizations.^[53] Data-driven approaches have introduced experimental datasets as shape priors in inverse design, leveraging diffusion models and surrogate neural networks to explore multifidelity spaces efficiently. For aerodynamic shapes, conditional diffusion-based sampling on NASA Common Research Model wing data has reduced training data needs by over 50%, generating diverse geometries that match high-fidelity CFD results within 5% error. These methods address limitations in purely physics-based techniques by using datasets from wind tunnel tests or material libraries to inform priors, accelerating convergence in underresolved inverse problems.^[54] Sustainability impacts are increasingly realized through shape optimizations that minimize material in electric vehicle (EV) battery casings, reducing carbon footprints via lightweight, multifunctional designs. Honeycomb-structured enclosures optimized for mass, natural frequency, and deformation have achieved 15-20% weight savings while enhancing crash protection, using finite element analysis to balance mechanical performance and recyclability. EU-funded initiatives under the BATT4EU partnership, including 2024-2025 projects like ENERGETIC, integrate such optimizations into battery manufacturing, targeting beyond-state-of-the-art lithium-ion cells with reduced environmental impact through modular casings and value chain efficiencies. These efforts align with EU goals for net-zero mobility, projecting lifecycle CO2 reductions of 10-15% per vehicle via optimized enclosures.^[55]^[56]

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Enforcing mesh quality constraints in shape optimization with a ...
In this paper, we present a novel, semi-discrete approach for enforcing a minimum mesh quality in shape optimization. Our approach is based on Rosen's gradient ...
[42]
A Survey on Design-Space Dimensionality Reduction Methods for ...
Sep 4, 2025 · This survey paper provides a comprehensive scoping review on dimensionality reduction techniques applied in the context of shape optimization.
[43]
A Survey on Design-space Dimensionality Reduction Methods for ...
May 22, 2024 · By integrating these methods into optimization frameworks, it is shown how they significantly mitigate the curse of dimensionality, streamline ...
[44]
Non-convex shape optimization by dissipative Hamiltonian flows
Feb 28, 2023 · In this paper, we adopt this strategy for non-convex shape optimization. In particular, we provide a mechanical shape optimization problem that is motivated by ...
[45]
On the relation between constraint regularization, level sets ... - arXiv
Nov 14, 2020 · Abstract:We consider regularization methods based on the coupling of Tikhonov regularization and projection strategies.
[46]
Effective adjoint approaches for computational fluid dynamics
Instead, the computational cost of adjoint methods scales with the number of functions of interest that need to be differentiated.
[47]
Adjoint-Based Aerodynamic Shape Optimization with a Manifold ...
Jul 31, 2025 · This manifold is enforced as an equality constraint to the shape optimization problem. Central to our method is the computation of adjoint ...
[48]
Geometric tolerance and manufacturing assemblability estimation of ...
This paper presents a methodology to conduct a geometric tolerance and manufacturing assemblability study of the parts manufactured by metal AM.
[49]
Shape Optimization of Heat Exchanger Fin Structures Using ... - MDPI
Mar 5, 2024 · The optimizations in 3D result in improvements in the heat transfer of a maximum of 3.5% at constant pressure loss or 9% lower pressure losses ...
[50]
Physics-informed shape optimization using coordinate projection
Mar 19, 2024 · We present a novel framework that employs neural network coordinate projection for shape optimization within PINN.Missing: seminal | Show results with:seminal
[51]
A CNN-PINN-DRL driven method for shape optimization of airfoils
The method of predicting aerodynamic performance of airfoils by PINN offers a viable alternative for optimizing and designing airfoils. It solves the non- ...
[52]
Evolutionary Optimization of Physics-Informed Neural Networks - arXiv
Oct 5, 2025 · This work examines PINNs in terms of model optimization and generalization, shedding light on the need for new algorithmic advances to overcome ...
[53]
Large-scale additive manufacturing of optimally-embedded spinodal ...
Mar 5, 2025 · We present a synergistic methodology to design large-scale 3D-printed structures based on a multi-material topology optimization formulation.
[54]
Topological Optimization and Generative Design for Additive ...
Jul 17, 2025 · The integration of additive manufacturing and topology optimization in the medical sector enables the creation of highly customized prostheses ...
[55]
Topology optimization of fluid‐structure interaction problems with ...
Oct 17, 2023 · This work extends force coupling in the topology optimization of fluid-structure interaction problems from hydrostatic to total stresses ...
[56]
Soft-Finite-Element-Method-Driven Multiphysics Airfoil Optimization
Nov 22, 2024 · Aerodynamic shape optimization cases (2D, 3D, and FSI) are reported in Sec. III to demonstrate the applicability of the proposed framework.Ii. Optimization Framework · B. Optimizer · Iii. Applications
[57]
(PDF) Data-Driven Aerodynamic Shape Optimization and ...
Jul 15, 2025 · Data-driven approaches have been shown to accelerate the process of high-fidelity design optimization, which has been successfully ...<|separator|>
[58]
Inverse design of 3D cellular materials with physics-guided machine ...
In most existing works, there are two main approaches to achieving the inverse design of cellular materials: optimization-based and data-driven-based methods.
[59]
Optimal design of honeycomb battery pack enclosure for electric ...
Oct 23, 2024 · A design of honeycomb battery pack enclosure is proposed based on mechanical parameters like mass of enclosure, natural frequency, and deformation for generic ...<|separator|>
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[PDF] BATT4EU Project Portfolio
Specific objectives are to (1) Develop high energy density, safe and manufacturable Lithium ion battery (2) optimise the full-cell chemistry to achieve beyond.