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Abstract Two‐scale topology optimization, combined with the design of microstructure families with a broad range of effective material parameters, is widely used in many fabrication applications to achieve a target deformation behavior for a variety of objects. The main idea of this approach is to optimize the distribution of material properties in the object partitioned into relatively coarse cells, and then replace each cell with microstructure geometry that mimics these material properties. In this paper, we focus on adapting this approach to complex shapes in situations when preserving the shape's surface is essential. Our approach extends any regular (i.e. defined on a regular lattice grid) microstructure family to complex shapes, by enriching it with tiles adapted to the geometry of the cut‐cell. We propose a fully automated and robust pipeline based on this approach, and we show that the performance of the regular microstructure family is only minimally affected by our extension while allowing its use on 2D and 3D shapes of high complexity. 

We introduce a general differentiable solver for time-dependent deformation problems with contact and friction. Our approach uses a finite element discretization with a high-order time integrator coupled with the recently proposed incremental potential contact method for handling contact and friction forces to solve ODE- and PDE-constrained optimization problems on scenes with complex geometry. It supports static and dynamic problems and differentiation with respect to all physical parameters involved in the physical problem description, which include shape, material parameters, friction parameters, and initial conditions. Our analytically derived adjoint formulation is efficient, with a small overhead (typically less than 10% for nonlinear problems) over the forward simulation, and shares many similarities with the forward problem, allowing the reuse of large parts of existing forward simulator code. We implement our approach on top of the open-source PolyFEM library and demonstrate the applicability of our solver to shape design, initial condition optimization, and material estimation on both simulated results and physical validations. 

Modern fabrication methods have greatly simplified manufacturing of complex free-form shapes at an affordable cost, and opened up new possibilities for improving functionality and customization through automatic optimization, shape optimization in particular. However, most existing shape optimization methods focus on single parts. In this work, we focus on supporting shape optimization for assemblies, more specifically, assemblies that are held together by contact and friction. Examples of which include furniture joints, construction set assemblies, certain types of prosthetic devices and many other. To enable this optimization, we present a framework supporting robust and accurate optimization of a number of important functionals, while enforcing constraints essential for assembly functionality: weight, stress, difficulty of putting the assembly together, and how reliably it stays together. Our framework is based on smoothed formulation of elasticity equations with contact, analytically derived shape derivatives, and robust remeshing to enable large changes of shape, and at the same time, maintain accuracy. We demonstrate the improvements it can achieve for a number of computational and experimental examples.