Multi-material topology optimization with interfacial stress constraints using body-fitted IGA

Multi-material topology optimization with interfacial stress constraints using body-fitted IGA | Research Square window.SnipcartSettings = { analytics: { enabled: false } }; (function() { var accessVector = localStorage.getItem('access_vector') || ''; window.dataLayer = window.dataLayer || []; if (accessVector) { window.dataLayer.push({ user: { profile: { profileInfo: { snid: accessVector } } } }); } })(); (function(w,d,s,l,i){w[l]=w[l]||[];w[l].push({'gtm.start':new Date().getTime(),event:'gtm.js'});var f=d.getElementsByTagName(s)[0],j=d.createElement(s),dl=l!='dataLayer'?'&l='+l:'';j.async=true;j.src='https://www.googletagmanager.com/gtm.js?id='+i+dl;f.parentNode.insertBefore(j,f);})(window,document,'script','dataLayer','GTM-K279D39R'); Browse Preprints In Review Journals COVID-19 Preprints AJE Video Bytes Research Tools Research Promotion AJE Professional Editing AJE Rubriq About Preprint Platform In Review Editorial Policies Our Team Advisory Board Help Center Sign In Submit a Preprint Cite Share Download PDF Research Article Multi-material topology optimization with interfacial stress constraints using body-fitted IGA Majd Kosta, Emad Shakur, Oded Amir This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-7465315/v1 This work is licensed under a CC BY 4.0 License Status: Posted Version 1 posted You are reading this latest preprint version Abstract This work presents a multi-material topology optimization method that incorporates interfacial stress constraints accurately. Using a precise boundary representation that is body-fitted to the evolving optimized topology, direct evaluations and control of both normal and shear stresses at material boundaries are achieved. Consistent sensitivity analysis is conducted following a discretize-then-differentiate approach, and optimization is performed using sequential convex programming. The method yields smooth, CAD-compatible geometries that reduce interfacial stress concentrations without the need for post-processing or artificial regularization. Several numerical examples demonstrate the capability of the framework to balance interfacial stresses with structural stiffness, while the optimized outcomes clearly exhibit the adaptation of the boundary to the allowable level of stress. Overall, the method provides a credible and physically consistent tool for structural design in boundary-sensitive, multi-material applications. Topology optimization IGA Multi-Material Stress-constrained Interfacial stresses Full Text Additional Declarations The authors declare no competing interests. Cite Share Download PDF Status: Posted Version 1 posted You are reading this latest preprint version Research Square lets you share your work early, gain feedback from the community, and start making changes to your manuscript prior to peer review in a journal. As a division of Research Square Company, we’re committed to making research communication faster, fairer, and more useful. We do this by developing innovative software and high quality services for the global research community. Our growing team is made up of researchers and industry professionals working together to solve the most critical problems facing scientific publishing. Also discoverable on Platform About Our Team In Review Editorial Policies Advisory Board Help Center Resources Author Services Accessibility API Access RSS feed Manage Cookie Preferences © Research Square 2026 | ISSN 2693-5015 (online) Privacy Policy Terms of Service Do Not Sell My Personal Information {"props":{"pageProps":{"initialData":{"identity":"rs-7465315","acceptedTermsAndConditions":true,"allowDirectSubmit":true,"archivedVersions":[],"articleType":"Research Article","associatedPublications":[],"authors":[{"id":505984648,"identity":"f97d1119-8f37-49f2-ae88-78cd0cf8f6a6","order_by":0,"name":"Majd Kosta","email":"data:image/png;base64,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","orcid":"https://orcid.org/0000-0001-5450-8860","institution":"Technion - Israel Institute of Technology","correspondingAuthor":true,"prefix":"","firstName":"Majd","middleName":"","lastName":"Kosta","suffix":""},{"id":505984649,"identity":"35426387-a80b-4441-b3ee-918efa80ed6e","order_by":1,"name":"Emad Shakur","email":"","orcid":"","institution":"Technion - Israel Institute of Technology","correspondingAuthor":false,"prefix":"","firstName":"Emad","middleName":"","lastName":"Shakur","suffix":""},{"id":505984650,"identity":"230fa906-cdd9-468b-863c-8c4f008f79c8","order_by":2,"name":"Oded Amir","email":"","orcid":"","institution":"Technion - Israel Institute of Technology","correspondingAuthor":false,"prefix":"","firstName":"Oded","middleName":"","lastName":"Amir","suffix":""}],"badges":[],"createdAt":"2025-08-26 17:38:41","currentVersionCode":1,"declarations":{"humanSubjects":false,"vertebrateSubjects":false,"conflictsOfInterestStatement":false,"humanSubjectEthicalGuidelines":false,"humanSubjectConsent":false,"humanSubjectClinicalTrial":false,"humanSubjectCaseReport":false,"vertebrateSubjectEthicalGuidelines":false},"doi":"10.21203/rs.3.rs-7465315/v1","doiUrl":"https://doi.org/10.21203/rs.3.rs-7465315/v1","draftVersion":[],"editorialEvents":[],"editorialNote":"","failedWorkflow":false,"files":[{"id":90146978,"identity":"3ca86827-3d84-4990-99d6-aff49d5fe401","added_by":"auto","created_at":"2025-08-29 06:01:00","extension":"pdf","order_by":1,"title":"","display":"","copyAsset":false,"role":"manuscript-pdf","size":20353282,"visible":true,"origin":"","legend":"","description":"","filename":"StressConstrainedSMO.pdf","url":"https://assets-eu.researchsquare.com/files/rs-7465315/v1_covered_9138be73-002c-46b2-a06d-10bb272dc4f7.pdf"}],"financialInterests":"The authors declare no competing interests.","formattedTitle":"\u003cp\u003eMulti-material topology optimization with interfacial stress constraints using body-fitted IGA\u003c/p\u003e","fulltext":[],"fulltextSource":"","fullText":"","funders":[{"identity":"9c667be5-3ace-4662-b169-f3c511bc7320","identifier":"10.13039/501100003977","name":"Israel Science Foundation","awardNumber":"2594/21","order_by":0}],"hasAdminPriorityOnWorkflow":false,"hasManuscriptDocX":false,"hasOptedInToPreprint":true,"hasPassedJournalQc":"","hasAnyPriority":true,"hideJournal":true,"highlight":"","institution":"Technion – Israel Institute of Technology","isAcceptedByJournal":false,"isAuthorSuppliedPdf":true,"isDeskRejected":"","isHiddenFromSearch":false,"isInQc":false,"isInWorkflow":false,"isPdf":true,"isPdfUpToDate":true,"isWithdrawnOrRetracted":false,"journal":{"display":true,"email":"[email protected]","identity":"researchsquare","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":true,"externalIdentity":"","sideBox":"","snPcode":"","submissionUrl":"/submission","title":"Research Square","twitterHandle":"researchsquare","acdcEnabled":true,"dfaEnabled":false,"editorialSystem":"","reportingPortfolio":"","inReviewEnabled":false,"inReviewRevisionsEnabled":true},"keywords":"Topology optimization, IGA, Multi-Material, Stress-constrained, Interfacial stresses","lastPublishedDoi":"10.21203/rs.3.rs-7465315/v1","lastPublishedDoiUrl":"https://doi.org/10.21203/rs.3.rs-7465315/v1","license":{"name":"CC BY 4.0","url":"https://creativecommons.org/licenses/by/4.0/"},"manuscriptAbstract":"\u003cp\u003eThis work presents a multi-material topology optimization method that incorporates interfacial stress constraints accurately.\u0026nbsp;Using a precise boundary representation that is body-fitted to the evolving optimized topology, direct evaluations and control of both normal and shear stresses at material boundaries are achieved.\u0026nbsp;Consistent sensitivity analysis is conducted following a discretize-then-differentiate approach, and optimization is performed using sequential convex programming. The method yields smooth, CAD-compatible geometries that reduce interfacial stress concentrations without the need for post-processing or artificial regularization.\u0026nbsp; Several numerical examples demonstrate the capability of the framework to balance interfacial stresses with structural stiffness, while the optimized outcomes clearly exhibit the adaptation of the boundary to the allowable level of stress.\u0026nbsp; Overall, the method provides a credible and physically consistent tool for structural design in boundary-sensitive, multi-material applications.\u0026nbsp;\u003c/p\u003e","manuscriptTitle":"Multi-material topology optimization with interfacial stress constraints using body-fitted IGA","msid":"","msnumber":"","nonDraftVersions":[{"code":1,"date":"2025-08-29 05:52:14","doi":"10.21203/rs.3.rs-7465315/v1","editorialEvents":[{"type":"communityComments","content":0}],"status":"published","journal":{"display":true,"email":"[email protected]","identity":"researchsquare","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":true,"externalIdentity":"","sideBox":"","snPcode":"","submissionUrl":"/submission","title":"Research Square","twitterHandle":"researchsquare","acdcEnabled":true,"dfaEnabled":false,"editorialSystem":"","reportingPortfolio":"","inReviewEnabled":false,"inReviewRevisionsEnabled":true}}],"origin":"","ownerIdentity":"d85606e1-b8b2-4ca6-bd70-4fa85a4c0e63","owner":[],"postedDate":"August 29th, 2025","published":true,"recentEditorialEvents":[],"rejectedJournal":[],"revision":"","amendment":"","status":"posted","subjectAreas":[],"tags":[],"updatedAt":"2025-08-29T05:52:15+00:00","versionOfRecord":[],"versionCreatedAt":"2025-08-29 05:52:14","video":"","vorDoi":"","vorDoiUrl":"","workflowStages":[]},"version":"v1","identity":"rs-7465315","journalConfig":"researchsquare"},"__N_SSP":true},"page":"/article/[identity]/[[...version]]","query":{"redirect":"/article/rs-7465315","identity":"rs-7465315","version":["v1"]},"buildId":"8U1c8b4HqxoKbykW_rLl7","isFallback":false,"isExperimentalCompile":false,"dynamicIds":[84888],"gssp":true,"scriptLoader":[]}