Structural Optimization Analysis Guide

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Table of Contents
1. Structural Optimization Overview .......................................................................................................... 1
2. Optimization Analysis Workflow ............................................................................................................ 3
2.1. Create User Defined Criteria .............................................................................................................. 3
2.1.1. Define Primary Criterion for the Measures Object ...................................................................... 4
2.1.2. Define Primary Criterion for a Harmonic Response Analysis ....................................................... 6
2.1.3. Define Primary Criterion for a Modal Analysis ............................................................................ 8
2.1.4. Define Primary Criterion for a Static Structural Analysis ............................................................. 9
2.1.5. Define Primary Criterion for a Steady-State Thermal Analysis ................................................... 11
2.1.6. Combine Primary Criterion Objects ......................................................................................... 12
2.1.7. Understanding the Criterion Calculations ............................................................................... 12
2.2. Create Upstream Analysis Systems .................................................................................................. 21
2.3. Attach Geometry and Launch Mechanical ....................................................................................... 23
2.4. Specify Analysis Settings ................................................................................................................. 24
2.5. Define Optimization Method and Regions ....................................................................................... 44
2.6. Determine Objective and Constraints Capabilities ........................................................................... 52
2.7. Define Design Objectives ................................................................................................................ 55
2.8. Define Response Constraints ........................................................................................................... 62
2.9. Define Manufacturing Constraints ................................................................................................... 72
2.10. Define Design Constraints ............................................................................................................. 83
2.11. Specify Results and Solve .............................................................................................................. 87
2.11.1. Topology Density ................................................................................................................. 88
2.11.2. Topology Elemental Density ................................................................................................. 92
2.11.3. Topology Multi-Density ........................................................................................................ 95
2.11.4. Structural Results ................................................................................................................. 97
2.11.5. Thermal Results .................................................................................................................. 100
2.12. Post Processing ........................................................................................................................... 103
2.13. Recreating CAD Geometry .......................................................................................................... 106
2.14. Performing Design Validation ...................................................................................................... 111
2.14.1. Geometry Validation ........................................................................................................... 112
2.14.2. Model Validation ................................................................................................................ 116
3. Design Methods .................................................................................................................................. 123
3.1. Shape Processing Workflows ......................................................................................................... 123
3.1.1. Density Based Topology Optimization Shape Processing ....................................................... 124
3.1.2. Level Set Based Topology Optimization Shape Processing ..................................................... 126
3.1.3. Lattice Optimization Shape Processing ................................................................................. 130
3.1.4. Shape Optimization Shape Processing .................................................................................. 132
3.1.5. Topography Optimization Shape Processing ......................................................................... 135
3.1.6. Materials Optimization Shape Processing .............................................................................. 138
3.2. Recommendations - Optimization in Practice ................................................................................ 140
3.2.1. Topology Optimization - Mixable Density .............................................................................. 140
3.2.2. Topology Optimization - Level Set Based ............................................................................... 142
3.2.3. Lattice Optimization Analysis ................................................................................................ 146
3.2.4. Shape Optimization Analysis ................................................................................................ 158
3.2.5. Topography Optimization ..................................................................................................... 161
3.2.6. Materials Optimization ......................................................................................................... 163
3.2.7. Topology Optimization - Density Based ................................................................................. 168
[Link]. Topology Optimization - Density Based Solution Methodology ..................................... 170
3.3. Mixing Multiple Methods within an Analysis .................................................................................. 174
3.4. Topology Optimization versus Shape Optimization ........................................................................ 175

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Structural Optimization Analysis Guide

4. Structural Optimization Theory .......................................................................................................... 177

4.1. Manufacturing Constraint Background .......................................................................................... 177
4.1.1. Member Size Minimum ........................................................................................................ 178
4.1.2. Member Size Maximum ........................................................................................................ 183
4.1.3. Member Size Gap Size .......................................................................................................... 195
4.1.4. Pull Out Direction ................................................................................................................. 204
4.1.5. Millability ............................................................................................................................. 237
4.1.6. Extrusion .............................................................................................................................. 242
4.1.7. AM Overhang Constraint ...................................................................................................... 252
4.1.8. Housing ............................................................................................................................... 257
4.1.9. Complexity Index ................................................................................................................. 260
4.2. Design Constraints Background .................................................................................................... 264
4.2.1. Cyclic Repetition .................................................................................................................. 264
4.2.2. Symmetry ............................................................................................................................ 268
4.2.3. Uniform ............................................................................................................................... 278
4.2.4. Pattern Repetition ................................................................................................................ 284
4.3. Local Design Restrictions .............................................................................................................. 288
4.3.1. Non-Optimizable Regions ..................................................................................................... 288
4.3.2. Bandwidth Constraints ......................................................................................................... 302
4.3.3. Directional Morphing ........................................................................................................... 321
5. Object Reference ................................................................................................................................. 333
5.1. Design Constraint ......................................................................................................................... 333
5.2. Local Design Restriction ................................................................................................................ 335
5.3. Manufacturing Constraint ............................................................................................................. 338
5.4. Objective ...................................................................................................................................... 340
5.5. Optimization Region ..................................................................................................................... 342
5.6. Response Constraint ..................................................................................................................... 345
6. Bibliography ........................................................................................................................................ 349

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List of Figures
4.1. Printing Angle Impact on Quality of Surface in FDM [15]. ..................................................................... 253
4.2. Overhanging Region (red) for Shape Ω Printed in Direction . .............................................................. 254

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List of Tables
4.1. AM Overhang Constraint Formulation ................................................................................................. 254
4.2. Setup Parameters and Technical Details ............................................................................................... 254
4.3. Local Design Restriction Properties by Optimization Type .................................................................... 289

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Chapter 1: Structural Optimization Overview
In the Ansys Mechanical application™, the Structural Optimization analysis is a form-finding analysis
driven by mechanical and geometrical criteria. The application obtains mechanical criteria from upstream
linear structural analyses (static, modal, harmonic, or thermal). The application also supports criteria
from non-linear structural analyses.

Optimization Methods
The application provides the following optimization methods:

• Topology Optimization:

– Density Based : This method performs optimization based on the density of each element of
your model. It employs Solid Isotropic Material with Penalization (SIMP) wherein density is
forced to approach 0 or 1 rather than varying continuously.

– Level Set: This method directly deals with the boundary of the shape. This enables Mechanical
to deliver an unambiguous solution.

– Mixable Density: This optimization type is using the same mathematical background as
density-based method but it has been enriched thanks to cross-fertilization with the Level-Set
based technology.

• Lattice Optimization: This method enables you to compute an optimal variable density lattice
distribution in your geometry.

• Shape Optimization: This method enables you to optimize the shape of your model by
morphing the mesh. As opposed to topology optimization, no topological change is allowed.
This method supports solid models only.

• Topography Optimization: This method enables you to perform shape optimization using mesh
node relocations. This method supports shell models only.

• Materials Optimization: This method enables you to determine the optimal distribution of dif-
ferent materials in one domain and lattice structures in one domain.

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Chapter 2: Optimization Analysis Workflow
The topics listed below describe the steps to create and perform an optimization analysis.
2.1. Create User Defined Criteria
2.2. Create Upstream Analysis Systems
2.3. Attach Geometry and Launch Mechanical
2.4. Specify Analysis Settings
2.5. Define Optimization Method and Regions
2.6. Determine Objective and Constraints Capabilities
2.7. Define Design Objectives
2.8. Define Response Constraints
2.9. Define Manufacturing Constraints
2.10. Define Design Constraints
2.11. Specify Results and Solve
2.12. Post Processing
2.13. Recreating CAD Geometry
2.14. Performing Design Validation

2.1. Create User Defined Criteria

You can define User Defined Criteria using the Primary Criterion and Composite Criterion objects. These
objects enable you to create scalar-based results on the mesh, or on the solution, of an upstream system.
This permits you to quantify the performance of your current design. In addition, you can use the result
data in a downstream Structural Optimization (p. 1) analysis as an Objective (p. 55) or as a Response
Constraint (p. 62). The User Defined Criterion options are available for the following:

• Measures Object (computes geometric quantities on the mesh)

• Harmonic Response Analysis

• Modal Analysis

• Static Structural Analysis

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Optimization Analysis Workflow

• Steady-State Thermal Analysis (p. 11) (Supported for Primary Criterion only)

Note:

When Beta Options are active, you can create User Defined Criteria as final result data in the
Structural Optimization analysis for the Objective (p. 55) object or as a Response Con-
straint (p. 62).

Depending upon your application (mesh or solution), the Primary Criterion object enables you to:

• Select a base result, such as mass, displacement, or reaction force.

• Set scoping options to generate the scalar value for an entity of interest (body, remote point,
boundary condition, etc.).

Note:

Based on how you specify criterion, using the Measures object or from the solution of
the upstream system, a prefix is added to the available options to indicate their source,
either "Meas:" or the analysis designation, such as "A5," "B5," etc.

To create more complex criterion, you can combine multiple scalar criteria (Primary Criterion objects)
into a single scalar value using the Composite Criterion object/option.

See the Understanding the Criterion Calculations (p. 12) section for a description of the calculations
used to obtain the criterion.

Application and Background

The following sections describe the steps to specify the Primary Criterion, how to combine your results
(via Composite Criterion object) as well as the formulas used to calculate the criterion.
2.1.1. Define Primary Criterion for the Measures Object
2.1.2. Define Primary Criterion for a Harmonic Response Analysis
2.1.3. Define Primary Criterion for a Modal Analysis
2.1.4. Define Primary Criterion for a Static Structural Analysis
2.1.5. Define Primary Criterion for a Steady-State Thermal Analysis
2.1.6. Combine Primary Criterion Objects
2.1.7. Understanding the Criterion Calculations

2.1.1. Define Primary Criterion for the Measures Object

To specify a Primary Criterion object under the Measures object:

1. To apply criteria to the mesh, first insert a Measures object from the Model Context tab or right-
click the Model object and select Insert > Measures.

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 Create User Defined Criteria

Once the Measures object is inserted, the Primary Criterion/Composite Criterion options are
available from the Measures Context tab, or by right-clicking the Measures object and selecting
Insert > Primary Criterion or Composite Criterion.

2. Select the desired Scoping Method. Options include:

• Geometry (default): Displays an associated Geometry selection property you use to select
a geometric entity using the Vertex, Edge, Face, or Body selection options.

• Named Selection: Displays an associated Named Selection property you use to select an
available user–defined Named Selection.

3. From the Base Result property, select the type of nodal vector field from which the extraction
occurs. Property options for this analysis type include:

• Mass

• Volume

• Center of Gravity

• Moment of Inertia

4. If symmetry is specified using either the Cyclic Region or Pre-Meshed Cyclic Region objects, the
Cyclic Reduction category and property become visible in the Details pane. The Base Sector
entry is read-only and indicates the supported geometry sector. This means that the application
performs calculations only on the base sector of the model.

5. As needed, change the Coordinate System. This property provides a drop-down list of available
coordinate systems. The selected coordinate system must be Cartesian. The default setting is
Global Coordinate System.

Note:

When the Base Result property is set to Moment of Inertia, this property also
includes and is automatically set to the option Coordinate System At Center
Of Gravity. Using this option means that the Moment of Inertia is computed with
respect to the center of gravity of the scoped geometry.

6. Specify the component of interest using the Reduction property. Options include:

• X, Y or Z: These options are available when the Base Result property is set to Center of
Gravity.

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Optimization Analysis Workflow

• Ixx, Iyy, Izz, Ixy, Ixz, Iyz: These options tensor component options are available when the
Base Result property is set to Moment of Inertia.

Note:

Note the following for the Component Reduction category:

• It is only available when the Base Result property is set to Center of Gravity
or Moment of Inertia.

• If specified, the application ignores Point Mass, Distributed Mass, and Impor-
ted Condensed Parts for the Primary Criterion computation.

• Only supported for 3D Flexible Bodies.

7. When you solve, the read-only Value property displays the calculated mass, volume, center of
gravity, or moment of inertia. You can parameterize this value.

See the Understanding the Criterion Calculations (p. 12) section for a description of the calculations
used to obtain the criterion.

2.1.2. Define Primary Criterion for a Harmonic Response Analysis

To specify a Primary Criterion object under the Solution object for a Harmonic Response analysis:

1. Select the Solution object and then select the Primary Criterion option from the Solution
Context tab, or right-click the Solution object and select Insert > User Defined Criteria >
Primary Criterion.

2. Select the desired Scoping Method. Options include:

• Geometry (default): Displays an associated Geometry selection property you use to select a
geometric entity using the Vertex, Edge, Face, or Body selection options.

Important:

This scoping only supports 3D flexible bodies.

Note:

If specified, the application ignores Point Mass, Distributed Mass, and Impor-
ted Condensed Parts for the Primary Criterion computation.

• Named Selection: Displays an associated Named Selection property you use to select an
available user-defined Named Selection.

• Remote Point: Displays an associated Remote Point property you use to select an available
user-defined Remote Point.

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 Create User Defined Criteria

• Boundary Condition: Displays an associated Boundary Condition property you use to select
either a Remote Force, Moment, or a Remote Displacement (the three supported boundary
conditions).

3. From the Base Result property, select the type of nodal vector field from which the extraction
occurs. Property options for this analysis type include:

• Displacement

• Velocity

• Acceleration

• Equivalent Radiated Power

4. No action is required for the Coordinate System property. This property is read-only and set to
Global Coordinate System.

5. Specify the component from which to extract node values using the Component Reduction
property. Options include:

• X/Y/Z (3D Only)

• Magnitude

• Face Normal (3D Face Selection Only)

• Directional

If you specify Directional, the Define By property displays. Options for the property include:

Component: When you select Component, the X/Y/Z (3D Only) Component properties
display. Set the value of these properties as either 0 or 1 in order to define the direction(s)
of interest. For example, specifying 1,0,0 for the components corresponds to a reduction
in the X direction.
Direction Selection: When you select Direction Selection, the Direction property displays.
Use this property to specify a direction by selecting an entity on the model.

6. Using the Spatial Reduction property, specify a desired computation method to produce a
scalar value from the scalar field on multiple nodes for each frequency. Options include Arith-
metic Average (default), Absolute Maximum, Continuous Average, and Standard Deviation.
This property is not available if you set the Base Result property to Equivalent Radiated Power

7. Specify the properties of the Frequency Reduction category. Properties include:

• Frequency Reduction: Except for the Equivalent Radiated Power option, this is a read-
only property set to Integration Over Frequency Range. For the Equivalent Radiated
Power selection, property options include Average, the standard arithmetic average, and
Average of Decibel Level that optimizes the ERP Level.

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Optimization Analysis Workflow

• Frequency Range: You use this property to define a desired frequency range. This produces
a scalar value from the vector field on multiple frequencies. Options include Use Parent
(default) and Manual. The Use Parent option uses the entire frequency range of the
analysis or you can use the manual option and specify a range. When you select the
Manual option, the Minimum Frequency and Maximum Frequency properties display
automatically so that you can enter values. These properties are read-only when you select
the Use Parent option.

8. After you solve the analysis, the read-only properties, Value and Discretization Error, display
the calculated displacement, velocity, or acceleration as well as an estimate of discretization error.
The discretization error result enables you to consider the quality of the chosen frequency spacing.
You can parameterize this value.

See the Understanding the Criterion Calculations (p. 12) section for a description of the calculations
used to obtain the criterion.

2.1.3. Define Primary Criterion for a Modal Analysis

To specify a Primary Criterion object under the Solution object for a Modal analysis:

1. Select the Solution object and then select the Primary Criteria option from the Solution Context
tab, or right-click the Solution object and select Insert > User Defined Criteria > Primary Cri-
teria.

2. Specify the setting of the Base Result property. Property options for this analysis type include:

• Single Frequency (default): Using this option, the application controls the i-th eigenfrequency
that you have selected in the mode number. During the optimization the mode order may
change, but the optimizer only focuses on the selected i-th eigenfrequency.

• Robust Frequencies: Using this option, the application controls the i-th eigenfrequency that
you have selected in the mode number, but also takes into account the presence of the other
eigenfrequencies per a weighted sum. The purpose of this option is to better manage the
mode-crossing effect, that is, modes order can change drastically during the solution and as
a result, cause the solver to prematurely converge and produce an undesirable design.

When you select this option, the Frequency Reduction property displays. Property options
include Average, Smooth Minimum, and Mode Tracking.

Note:

The rank of any eigenmode may change during the optimization. The Mode
Tracking option enables you to track a mode of interest, as long as it does not
change drastically during the optimization process.

3. Specify a Mode Number that corresponds to the eigenfrequency you wish to observe. The default
setting is 1. The entry range depends on the number of modes that you have requested in the
upstream modal analysis, which has a default setting of 6.

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 Create User Defined Criteria

4. When you solve, the read-only Value property displays the calculated frequency or frequencies.
You can parameterize this value.

See the Understanding the Criterion Calculations (p. 12) section for a description of the calculations
used to obtain the criterion.

Note:

If Beta Options are active, Modal analyses support User Defined Criteria when you also in-
clude a Cyclic Region or a Pre-Meshed Cyclic Region object. Mode Tracking is not supported
for the Robust Frequencies setting.

2.1.4. Define Primary Criterion for a Static Structural Analysis

To specify a Primary Criterion object under the Solution object for a Static Structural analysis:

1. Select the Solution object and then select the Primary Criterion option from the Solution
Context tab, or right-click the Solution object and select Insert > User Defined Criteria >
Primary Criterion.

2. Select the desired Scoping Method. Options include:

• Geometry (default): Displays an associated Geometry selection property you use to select a
geometric entity using the Vertex, Edge, Face, or Body selection options.

Important:

This scoping only supports 3D flexible bodies.

Note:

If specified, the application ignores Point Mass, Distributed Mass, and Impor-
ted Condensed Parts for the Primary Criterion computation.

• Named Selection: Displays an associated Named Selection property you use to select an
available user–defined Named Selection.

• Remote Point: Displays an associated Remote Point property you use to select an available
user–defined Remote Point.

• Boundary Condition: Displays an associated Boundary Condition property you use to select
either a Remote Force, Moment, or a Remote Displacement (the three supported boundary
conditions).

3. From the Base Result property, select the type of nodal vector field from which the extraction
occurs. Property options for this analysis type include:

• Displacement

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Optimization Analysis Workflow

• Rotation

• Reaction Force

• Reaction Moment

4. If symmetry is specified using either the Cyclic Region or Pre-Meshed Cyclic Region objects, the
Cyclic Reduction category and property become visible in the Details pane. The Base Sector
entry is read-only and indicates the supported geometry sector. This means that the application
performs calculations only on the base sector of the model.

5. In the Load Step Selection category, specify a desired Load Step for which to compute the cri-
terion using the Step property.

6. Specify the component from which to extract node values using the Component Reduction
property. Options include:

• X/Y/Z (3D Only)

• Magnitude

• Face Normal (3D Face Selection Only)

• Directional

If you specify Directional, the Define By property displays. Options for the property include:

Component: When you select Component, the X/Y/Z (3D Only) Component properties
display. Set the value of these properties as either 0 or 1 in order to define the direction(s)
of interest. For example, specifying 1,0,0 for the components corresponds to a reduction
in the X direction.
Direction Selection: When you select Direction Selection, the Direction property displays.
Use this property to specify a direction by selecting an entity on the model.

7. Using the Spatial ReductionTip (p. 10) property, specify a desired computation method to produce
a scalar value from the scalar field on multiple nodes. Options include Arithmetic Average (de-
fault), Absolute Maximum, and Continuous Average and Standard Deviation for the Displace-
ment and Rotation options of the Base Result property and Sum for the Reaction Force and
Reaction Moment options.

8. When you solve, the read-only Value property displays the calculated displacement, rotation,
force, or torque. You can parameterize this value.

See the Understanding the Criterion Calculations (p. 12) section for a description of the calculations
used to obtain the criterion.

Tip

Devise a More Advanced Criterion - Deviation Control

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 Create User Defined Criteria

When combining the Spatial Reduction property of the Primary and Composite Criterion objects,
you can devise a control of the deviation over the scoping region, specifically, the gap between
the maximum and the average. Procedure:

1. Insert a Primary Criterion object, specify a desired scoping and the base result, and set
the Spatial Reduction property to Absolute Maximum.

2. Repeat the above step and set the Spatial Reduction property to Arithmetic Average.

3. Insert a Composite Criterion object, specify the above Primary Criteria definitions, and
specify a Coefficient of 1.0 and -1.0, respectively.

You can now use the Composite Criterion to specify a Criterion Constraint (p. 62) or the Object-
ive (p. 55) object in the downstream Structural Optimization analysis.

2.1.5. Define Primary Criterion for a Steady-State Thermal Analysis

To specify a Primary Criterion object under the Solution object for a Steady-State Thermal analysis:

1. Select the Solution object and then select the Primary Criterion option from the Solution
Context tab, or right-click the Solution object and select Insert > User Defined Criteria >
Primary Criterion.

2. Select the desired Scoping Method. Options include:

• Geometry (default): Displays an associated Geometry selection property you use to select a
geometric entity using the Vertex, Edge, Face, or Body selection options.

Important:

This scoping only supports 3D flexible bodies.

Note:

If specified, the application ignores Point Mass, Distributed Mass, and Impor-
ted Condensed Parts for the Primary Criterion computation.

• Named Selection: Displays an associated Named Selection property you use to select an
available user–defined Named Selection.

3. From the Base Result property, select the type of nodal vector field from which the extraction
occurs. The only option for this analysis type is Temperature.

4. In the Load Step Selection category, specify a desired Load Step for which to compute the cri-
terion using the Step property.

5. Using the Spatial Reduction property, specify a desired computation method to produce a
scalar value from the vector field on multiple nodes. Options include Arithmetic Average (default),
Absolute Maximum, Continuous Average, and Standard Deviation.

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Optimization Analysis Workflow

6. When you solve, the read-only Value property displays the calculated temperature. You can
parameterize this value.

See the Understanding the Criterion Calculations (p. 12) section for a description of the calculations
used to obtain the criterion.

2.1.6. Combine Primary Criterion Objects

For one or more defined Primary Criterion objects, you can use the Composite Criterion option/object.
When inserted, the Worksheet displays automatically. Using the table and its options, add the Primary
Criterion objects you wish to combine. You need to add a row for each object. As needed, specify
Coefficient values for your entries.

Once solved, the Composite Criterion result is displayed by the Value property.

2.1.7. Understanding the Criterion Calculations

The following topics describe the calculations for the methods and base results as well as the Com-
posite Criterion.

• Measures Object (p. 13)

• Harmonic Response Analysis (p. 15)

• Modal Analysis (p. 17)

• Static Structural Analysis (p. 18)

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 Create User Defined Criteria

• Steady-State Thermal Analysis (p. 19)

• Composite Criterion (p. 20)

Measures Object
Mass

The criterion calculation:

Given , the volumetric mass of the body, and , the mass formula of the k-th body reads
(continuous and discretized):

Where and are the volume and resp. the volumetric mass of the e-th element.

Note:

The volume criterion uses the same formula with .

In the context of topology optimization, the formula reads:

Where is the density parameter of the e-th element. This is a unit-less multiplier
with a range of 0.0 to 1.0.

Center of Gravity

For Center of Gravity, you can choose the component of interest (x, y or z).

Given X = (x, y, z), a material point within the body, the formula reads (continuous):

The sum over the k-th body of interest.

After discretization:

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Optimization Analysis Workflow

Where:

is the centroid of the e-th element.

other quantities are defined above

Notes:

is given with respect to the global coordinate system.

for a coordinate system: where P is the rotation matrix.

Moment of Inertia

The Moment of Inertia is by nature a tensor. You can choose the component of interest (Ixx, Iyy,
Izz, Ixy, Ixz, Iyz).

The full tensor with respect to the global coordinate system reads (continuous formula):

After discretization:

Note:

is given with respect to the global coordinate system (origin = 0).

With respect to the Center of Gravity (G) the formula now reads:

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 Create User Defined Criteria

Where is the total mass of the body scoping.

And is the 3 x 3 identity matrix.

Harmonic Response Analysis

Primary Criteria

The goal of the User Defined Criterion feature is to define a singular scalar value that measures
the mechanical performance of a design as a result of the following three-step reduction process:

1. Component reduction that converts a base-result (namely a complex-valued spatial vector-

field, defined for every excitation frequency) onto a spatial scalar-field defined for every
excitation frequency.

2. Spatial reduction that transforms the component-reduced field into a singular scalar value
defined for every excitation frequency.

3. Frequency reduction that aggregates the spatially-reduced field into a singular scalar
value.

Here is an example of the computation process for a displacement base result:

Component reduction returns a spatial scalar field, defined for every excitation frequency:

Spatial reduction returns a singular value, defined for every excitation frequency:

After discretization, generally reads:

Frequency reduction returns a singular scalar value, the criterion:

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Optimization Analysis Workflow

After discretization, the criterion reads:

where:

NodeSet is the set of nodes defined by the scoping.

FrequencySet is the set of frequencies defined by the Frequency Reduction.
is the Frequency Range of the criterion:

is the excitation frequency.

is the quantity obtained by component reduction.

Considering the displacement as a base result, its complex harmonic amplitude is a

complex-valued vector field that reads:

Then the different component reductions are:

is the weight of each node of the NodeSet.

This parameter is related to the following Spatial Reduction when the property is set to Arith-
metic Average:

(Based on scoping, can be the volume of influence, the surface of influence or the length of
influence).

When the Spatial Reduction property is set to Absolute Maximum, the criterion is defined as:

However, in order for this calculation to be derivable, the max operator is approximated. The
calculation uses the absolute values of the result.

The Frequency Reduction property is a read-only property set to Average.

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 Create User Defined Criteria

When the Spatial Reduction property is set to Standard Deviation, the criterion is defined as:

Where:
N is the number of nodes in the NodeSet.
is the average value of the for a given excitation frequency.

Note:

• The frequency reduction process naturally introduces discretization error in the cri-
terion evaluation. The application calculates an estimate for this error. If it exceeds
10% of the criterion value, then a corresponding message appears in the Optimization
Output.

• If the calculated displacement, velocity, or acceleration presented in the Value

property is close to or equals zero, then the Discretization Error property is always
set to 0%.

Modal Analysis
Primary Criterion

For the Robust Frequencies setting, the criterion reads:

Where:

• is the selected mode of interest (Mode property).

For the Average reduction frequency, the weight is the same for all frequencies, that is:

For the Smooth Minimum setting, the weight is given by:

This expression provide an acceptable approximation of the true minimum, while remaining de-
rivable, which is compulsory to be used in an optimization problem.

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Optimization Analysis Workflow

Static Structural Analysis

Primary Criterion

The goal of the User Defined Criterion feature is to define a singular scalar value that measures
the mechanical performance of a design as a result of the following two-step reduction process:

1. Component Reduction that converts a base-result (namely a spatial vector-field) onto a

spatial scalar-field.

2. Spatial Reduction that transforms the spatial scalar-field onto a singular scalar value.

Here is an example of the computation process for a displacement base result:

• Component reduction returns a spatial scalar field:

• Spatial reduction returns a singular value, the criterion (Crit):

After discretization, the criterion generally reads:

Where:

• NodeSet is the set of nodes defined by the scoping.

• i is the specified load step (Current Step Number property).

• is the quantity obtained by component reduction.

Considering the displacement as a base result, the different component reductions are:

For Spatial Reduction set to Arithmetic Average: . Not available when

the Base Result property is set to Reaction Force or Reaction Moment.

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 Create User Defined Criteria

For Spatial Reduction set to Sum:

is the weight of each node of the NodeSet. This parameter is related to the following Spatial
Reduction property:

(Based on scoping, , can be the volume of influence, the surface of influence, or the length
of influence).

When the Spatial Reduction property set to Absolute Maximum, the criterion is defined as:

However, in order for this calculation be derived, the maximum (max) criterion is approximated.
The calculation uses the absolute values of the result.

Note:

When the Base Result property is set to Reaction Force and the Component Reduction
property is set to Magnitude, the formula of the criterion reads:

[where: (Rnx, Rny, Rnz) = the (x, y, z) reaction

force at the n-th node.

When the Spatial Reduction property is set to Standard Deviation, the criterion is defined as:

Where:
N is the number of nodes in the NodeSet.
is the average value of the is the average value of over the NodeSet.

Steady-State Thermal Analysis

Primary Criterion

The goal of the User Defined Criterion feature is to define a singular scalar value that measures
the mechanical performance of a design as a result of the following spatial reduction process that
transforms the spatial scalar-field onto a singular scalar value.

Here is an example of the computation process for a temperature base result, spatial reduction
returns a singular value, the criterion (Crit):

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Optimization Analysis Workflow

After discretization, the criterion generally reads:

Where:

• NodeSet is the set of nodes defined by the scoping.

• i is the specified load step (Current Step Number property).

• is the quantity obtained from the solution.

For Spatial Reduction set to Arithmetic Average: .

When the Spatial Reduction property set to Absolute Maximum, the criterion is defined as:

However, in order for this calculation be derived, the maximum (max) criterion is approximated.
The calculation uses the absolute values of the result.

When the Spatial Reduction property is set to Standard Deviation, the criterion is defined as:

Where:
N is the number of nodes in the NodeSet.
is the average value of the is the average value of over the NodeSet.

Composite Criterion
Using the Composite Criterion object, you combine several primary criteria into a single scalar value.
The composite criteria is computed as a weighted sum of Primary Criteria.

Where:

is the composite criterion value.

are respectively the weights and primary criteria values.

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 Create Upstream Analysis Systems

2.2. Create Upstream Analysis Systems

An optimization analysis requires an upstream "feeder" system that provides the loading and/or
boundary conditions used to create an optimized part based on the Objective (p. 55) and Response
Constraint (p. 62) objects specified in the optimization analysis.

Supported Upstream Systems

The optimization analysis must be linked to (preceded by) one of the following analysis types:

• Harmonic Response

• Modal

• Static Structural/Static Structural Nonlinear

• Steady-State Thermal

• Any combination of Harmonic Response, Modal, Static Structural, and/or Steady-State Thermal.

Model Level Object Specifications

The Model object enables you to define objects used by all of the analysis types specified in your sim-
ulation. Structural Optimization analyses support the following model-level features:

• Symmetry specified using the Cyclic or Pre-Meshed Cyclic objects. The optimization process considers
both of these symmetry types during shape derivative computations. Supported analysis types include:

– Topology Optimization - Mixable Density

– Topology Optimization - Level Set Based

– Shape Optimization

Note:

To make sure that the geometry remains compatible with cyclic symmetry, the Shape
Optimization method automatically considers the faces of the Low Selection and
High Selection of the cyclic region to be non-optimizable.

• Condensed Parts when you have an upstream Harmonic Response, Modal, or Static Structural
(linear only) analysis.

Procedure
1. Specify your upstream system or systems. Drag the system from the Toolbox to the Project
Schematic or double-click the system in the Toolbox. The cells between the systems should be
linked as illustrated below.

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Optimization Analysis Workflow

2. Link your systems as illustrated in the examples shown below. The new Structural Optimization
system shares the Engineering Data, Geometry, and Model cells with the same cells as the up-
stream systems and the Solution cell links to the Setup cell of the Structural Optimization system.

Upstream Static Structural System Example

Multiple Upstream Systems Example

If necessary, link the Solution cell of the Static Structural or Modal analysis to the Setup cell of
the Structural Optimization system.

Note:

• If your upstream system is a single Static Structural analysis, Ansys recommends that
you use step-based loading to improve scalability. In order to do so, you need to
define your loading conditions using the Tabular Data window and you need to set
the Independent Variable property to the Step option. This does not include the
use of the Thermal Condition load.

• When you specify a Structural Optimization system from Mechanical, you need to
make sure that you connect the systems properly. Connect the systems using the
Transfer Data From context (right-click) menu option from the Structural Optimiz-

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 Attach Geometry and Launch Mechanical

ation environment. Once linked, you can disconnect the systems using the Unlink
Data From option of the context menu.

Once you link the analyses, automatic property specifications are made in Mechanical to define the re-
lationship between the systems.

2.3. Attach Geometry and Launch Mechanical

The procedure below assumes that you have a supported geometry file type. As needed, review the
Attach Geometry/Mesh section for a description of the available methods and supported file types.

Procedure
1. Right-click the Geometry cell of the (furthest) upstream system, select Import > Browse and select
the desired file for import. Note that double-clicking on the Geometry cell opens Discovery Mod-
eling.

Important:

This analysis does not support the presence of a Rigid Body.

2. Once you have your geometry specified, double-click the Model cell (or right-click, and select Edit)
of any of the systems to launch the Mechanical application.

3. Once your geometry is loaded in Mechanical, review how it is presented in the project tree. Note
that the Future Analysis property of the Analysis Data Management Category in the Analysis
Settings object of the upstream system is specified as Structural Optimization. And, the Environ-
ment Selection List property of the Solution object of the optimization system shows the cell
identifiers of the environments linked to the current optimization environment, as illustrated below

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Optimization Analysis Workflow

Note:

Also illustrated above, the application automatically inserts and assigns default values
to the Optimization Region, Objective, and Response Constraint objects in the op-
timization analysis.

2.4. Specify Analysis Settings

This topic examines the application defaults for Analysis Settings properties based on the optimization
method. For a general overview of the use of analysis settings, see the Establish Analysis Settings section.

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 Specify Analysis Settings

Analysis Settings per Method

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Optimization Analysis Workflow

Density Based Optimization

For the Topology Optimization - Density Based method, you can modify the properties as de-
scribed below.

Reload Volume Analysis

The Reload Volume Analysis category of the Analysis Settings is only available when per-
forming a Structural Optimization analysis and it only displays following the solution process.
This category includes the Reload Volume Fraction property. The options for this property
include Off and Manual. When you set the property to Manual, the Current Reload Point
property also displays and provides the following options:

• Initial: Using this setting, your next solution begins from Iteration 0 (a new solution).

• Iteration Number ##: This setting is based on the last Iteration completed for the
previous solution. Using this setting, your next solution begins by reloading the volume
fractions at the specified iteration number.

Note:

When you pick a reload point that is different from the Initial reload point,
you may receive an optimized shape that is different than the optimized shape
obtained when you perform the optimization from the beginning of the ana-
lysis.

Important:

If you modify any of the following, the Reload Volume Analysis category disappears
from the Analysis Settings:

• Manufacturing Constraints (You can use the Pull Out Direction Manufactur-
ing Constraint for Reload Volume Analysis if you set the Region of Manu-
facturing Constraint property to Exclude Exclusion)

• Optimization Region

• Region of Manufacturing Constraint property

• Region of Min Member property

• Size property

• Any associated upstream system

Definition Category

The Definition category of the Analysis Settings is only available when performing a Struc-
tural Optimization analysis. The properties of the Definition category include:

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 Specify Analysis Settings

• Maximum Number of Iterations: This property specifies the maximum number of iter-
ations performed for the Structural Optimization analysis. The solution process continues
until the application achieves convergence accuracy or reaches the maximum number
of iterations. The default value is 500.

• Minimum Normalized Density: This property requires a value greater than 0 and less
than 1. The Structural Optimization analysis uses this value to extract the permissible
range of retained threshold values. The default value is 0.001.

• Convergence Accuracy: This property specifies the convergence criteria of the Struc-
tural Optimization analysis. The solution process continues until the application achieves
convergence accuracy or reaches the maximum number of iterations. This value must
be less than or equal to 2. The default value is 0.1%.

Note:

Specifying a lower Convergence Accuracy, for example 0.05%, is re-

commended if your optimization objective is to minimize Mass/Volume
with Global/Local von-Mises stress constraint.

• Initial Volume Fraction: This property requires a value greater than 0 and less than
or equal to 1. The optimization analysis uses this value as an initial estimate for the
volume fraction. All optimized elements begin with this value. By default, the application
uses your specified Objectives and Constraints to determine the initial estimate. A value
of 1 indicates full material, whereas all other values indicate a fraction of the original
material.

• Penalty Factor (Stiffness): During the solution process, this property applies a penalty
factor to the structural stiffness matrix in order to prevent the stiffness matrix from
scaling linearly with the pseudo density. Therefore, the stiffness at each iteration, as
needed, is modified using the expression: . The
default value is 3.

• Region of Manufacturing Constraint: The options for this property are Include Exclu-
sions (default) and Exclude Exclusions. When you specify Include Exclusions, the
application also incorporates the Exclusion Region (p. 44) to satisfy the Pull Out Dir-
ection, Extrusion, Cyclic Repetition, and Symmetry manufacturing constraints.

• Region of Min Member Size: The options for this property are Include Exclusions
and Exclude Exclusions (default). When you specify Include Exclusions, the application
also incorporates the Exclusion Region (p. 44) to meet the minimum member size
specified through the Member Size manufacturing constraint.

• Region of AM Overhang Constraint: If your analysis includes the specifications of an

AM Overhang Constraint, this property enables you to include or exclude the object
on the Exclusion Region (p. 44) of the model. The options for this property are Include
Exclusions and Exclude Exclusions (default). When you specify Include Exclusions,
the application applies the AM Overhang Constraint to the Exclusion Region.

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Optimization Analysis Workflow

• Filter (Density Based method only): This property specifies the method used to calculate
the pseudo density of each element. Options include:

– Linear: A faster processing option than Non-Linear, this option may prefer placing
material on the boundary of your design domain as well as cause the Minimum
value of the Member Size property to infringe upon the boundary of the design
domain.

– Non-Linear (Program Controlled default): This option uses more advanced al-
gorithms to calculate the pseudo densities that resolve the drawbacks of linear
filtering.

Note:

Ansys recommends that you exclude all areas where loads are applied.

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 Specify Analysis Settings

Output Controls

The properties of the Output Controls category include:

• Export Design Properties. This property is only available for a Structural Optimization
analysis when you have an upstream Modal, Static Structural, or Thermal analysis system.
Upstream Harmonic Response analyses do not support the export of structural results.
You use the options when the application creates solution data. You can then create
results in your Structural Optimization analysis that correspond to your upstream ana-
lysis. These results enable you to examine the mechanical behavior of your optimal
design (corresponding to the last accepted iteration) as well as the mechanical behavior
of intermediate designs. Property options include:

– No (default): No solution data is generated.

– On Final Design: Solution data is created at the end of the optimization process.
This corresponds to the last accepted iteration (optimal design).

– All Accepted Iterations: Solution data is generated after each accepted iteration of
the optimization process. That is, the solution data includes all accepted iterations.

– Last Accepted Iteration: Solution data is generated during the optimization process
that corresponds to the last accepted iteration. That is, the single data is updated
during the optimization in accordance with the latest accepted design.

Export Design Properties File Format: This property displays when you specify
the Export Design Properties property. Options include HDF5 File (default) and
VTK File (requires external reader).

Important:

Strain-based results are not supported for the Topology Optimization -

Density Based method.

Note:

These structural results are displayed on a triangle-based surface-mesh.

• Store Results At: Based on the analysis type, specify this time to be All Time Points
or All Iterations (default setting), Last Time Point or Last Iteration, Equally Spaced
Points or Specified Recurrence Rate.

Value. Displayed only if Store Results At is set to Equally Spaced Points or Spe-
cified Recurrence Rate.

See Output Controls section for additional information about the properties of this category.

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Optimization Analysis Workflow

Solver Controls Category

The Solver Type property is the only property for this category. The property's options include:

• Program Controlled (default): The application selects the Sequential Convex Program-
ming solver as the default option.

• Sequential Convex Programming: The Sequential Convex Programming method is

an extension of the method of moving asymptotes (MMA). The Sequential Convex
Programming method requires the derivatives of all functions present in the Structural
Optimization analysis.

See the Optimization Solver Methods (p. 170) section for additional technical detail
about this solver type.

• Optimality Criteria: The Optimality Criteria method can be used to solve Structural
Optimization problems with a simple compliance objective that uses a volume or mass
constraint.

Note:

The following support limitations apply to the Optimality Criteria

method:

– Only supports the Compliance (Structural) setting for the Re-

sponse Type column of the Objective object worksheet.

– Only Volume and Mass constraints are supported.

– The Manufacturing Constraint is supported where only the

Minimum property for the Member Size constraint subtype can
be specified.

See the Optimization Solver Methods (p. 170) section for additional technical details
about this solver type.

Analysis Data Management Category

See the Analysis Data Management Category section of the Help for additional information
about the properties of this category.

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 Specify Analysis Settings

Level Set Based Optimization

For the Topology Optimization - Level Set Based method, you can modify the properties as
described below.

Definition Category

The Definition category of the Analysis Settings is only available when performing a Struc-
tural Optimization analysis. The properties of the Definition category include:

• Maximum Number of Iterations: This property specifies the maximum number of iter-
ations performed for the Structural Optimization analysis. The solution process continues
until the application achieves convergence accuracy or reaches the maximum number
of iterations. The default value is 500.

• Convergence Accuracy: This property specifies the convergence criteria of the Struc-
tural Optimization analysis. The solution process continues until the application achieves
convergence accuracy or reaches the maximum number of iterations. The default value
is 0.1%.

Output Controls

The properties of the Output Controls category include:

• Export Design Properties. This property is only available for a Structural Optimization
analysis when you have an upstream Modal, Static Structural, or Thermal analysis system.
Upstream Harmonic Response analyses do not support the export of structural results.
You use the options when the application creates solution data. You can then create
results in your Structural Optimization analysis that correspond to your upstream ana-
lysis. These results enable you to examine the mechanical behavior of your optimal
design (corresponding to the last accepted iteration) as well as the mechanical behavior
of intermediate designs. Property options include:

– No (default): No solution data is generated.

– On Final Design: Solution data is created at the end of the optimization process.
This corresponds to the last accepted iteration (optimal design).

– All Accepted Iterations: Solution data is generated after each accepted iteration of
the optimization process. That is, the solution data includes all accepted iterations.

– Last Accepted Iteration: Solution data is generated during the optimization process
that corresponds to the last accepted iteration. That is, the single data is updated
during the optimization in accordance with the latest accepted design.

Export Design Properties File Format: This property displays when you specify
the Export Design Properties property. Options include HDF5 File (default) and
VTK File (requires external reader).

Note:

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Optimization Analysis Workflow

These structural results are displayed on a triangle-based surface-mesh.

• Store Results At: Based on the analysis type, specify this time to be All Time Points
or All Iterations (default setting), Last Time Point or Last Iteration, Equally Spaced
Points or Specified Recurrence Rate.

Value. Displayed only if Store Results At is set to Equally Spaced Points or Spe-
cified Recurrence Rate.

See Output Controls section for additional information about the properties of this category.

Analysis Data Management Category

See the Analysis Data Management Category section of the Help for additional information
about the properties of this category.

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 Specify Analysis Settings

Lattice Optimization

For the Lattice Optimization method, you can modify the properties as described below.

Reload Volume Analysis

The Reload Volume Analysis category of the Analysis Settings is only available when per-
forming a Structural Optimization analysis and it only displays following the solution process.
This category includes the Reload Volume Fraction property. The options for this property
include Off and Manual. When you set the property to Manual, the Current Reload Point
property also displays and provides the following options:

• Initial: Using this setting, your next solution begins from Iteration 0 (a new solution).

• Iteration Number ##: This setting is based on the last Iteration completed for the
previous solution. Using this setting, your next solution begins by reloading the volume
fractions at the specified iteration number.

Note:

When you pick a reload point that is different from the Initial reload point,
you may receive an optimized shape that is different than the optimized shape
obtained when you perform the optimization from the beginning of the ana-
lysis.

Important:

If you modify any of the following, the Reload Volume Analysis category disappears
from the Analysis Settings:

• Manufacturing Constraints (You can use the Pull Out Direction Manufactur-
ing Constraint for Reload Volume Analysis if you set the Region of Manu-
facturing Constraint property to Exclude Exclusion)

• Optimization Region

• Region of Manufacturing Constraint property

• Region of Min Member property

• Size property

• Any associated upstream system

Definition Category

The Definition category of the Analysis Settings is only available when performing a Struc-
tural Optimization analysis. The properties of the Definition category include:

• Maximum Number of Iterations: This property specifies the maximum number of iter-
ations performed for the Structural Optimization analysis. The solution process continues

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Optimization Analysis Workflow

until the application achieves convergence accuracy or reaches the maximum number
of iterations. The default value is 500.

• Minimum Normalized Density: This property requires a value greater than 0 and less
than 1. The Structural Optimization analysis uses this value to extract the permissible
range of retained threshold values. The default value is 0.001.

• Convergence Accuracy: This property specifies the convergence criteria of the Struc-
tural Optimization analysis. The solution process continues until the application achieves
convergence accuracy or reaches the maximum number of iterations. This value must
be less than or equal to 2. The default value is 0.1%.

Note:

Specifying a lower Convergence Accuracy, for example 0.05%, is re-

commended if your optimization objective is to minimize Mass/Volume
with Global/Local von-Mises stress constraint.

• Initial Volume Fraction: This property requires a value greater than 0 and less than
or equal to 1. The optimization analysis uses this value as an initial estimate for the
volume fraction. All optimized elements begin with this value. By default, the application
uses your specified Objectives and Constraints to determine the initial estimate. A value
of 1 indicates full material, whereas all other values indicate a fraction of the original
material.

• Region of Manufacturing Constraint: The options for this property are Include Exclu-
sions (default) and Exclude Exclusions. When you specify Include Exclusions, the
application also incorporates the Exclusion Region (p. 44) to satisfy the Pull Out Dir-
ection, Extrusion, Cyclic Repetition, and Symmetry manufacturing constraints.

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 Specify Analysis Settings

Output Controls

The properties of the Output Controls category include:

• Export Design Properties. This property is only available for a Structural Optimization
analysis when you have an upstream Modal, Static Structural, or Thermal analysis system.
Upstream Harmonic Response analyses do not support the export of structural results.
You use the options when the application creates solution data. You can then create
results in your Structural Optimization analysis that correspond to your upstream ana-
lysis. These results enable you to examine the mechanical behavior of your optimal
design (corresponding to the last accepted iteration) as well as the mechanical behavior
of intermediate designs. Property options include:

– No (default): No solution data is generated.

– On Final Design: Solution data is created at the end of the optimization process.
This corresponds to the last accepted iteration (optimal design).

– All Accepted Iterations: Solution data is generated after each accepted iteration of
the optimization process. That is, the solution data includes all accepted iterations.

– Last Accepted Iteration: Solution data is generated during the optimization process
that corresponds to the last accepted iteration. That is, the single data is updated
during the optimization in accordance with the latest accepted design.

Export Design Properties File Format: This property displays when you specify
the Export Design Properties property. Options include HDF5 File (default) and
VTK File (requires external reader).

Note:

These structural results are displayed on a triangle-based surface-mesh.

• Store Results At: Based on the analysis type, specify this time to be All Time Points
or All Iterations (default setting), Last Time Point or Last Iteration, Equally Spaced
Points or Specified Recurrence Rate.

Value. Displayed only if Store Results At is set to Equally Spaced Points or Spe-
cified Recurrence Rate.

See Output Controls section for additional information about the properties of this category.

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Optimization Analysis Workflow

Solver Controls Category

The Solver Type property is the only property for this category. The property options include:

• Program Controlled (default): The application selects the Sequential Convex Program-
ming solver as the default option.

• Sequential Convex Programming: The Sequential Convex Programming method is

an extension of the method of moving asymptotes (MMA). The Sequential Convex
Programming method requires the derivatives of all functions present in the Structural
Optimization analysis.

See the Optimization Solver Methods (p. 170) section for additional technical detail
about this solver type.

• Optimality Criteria: The Optimality Criteria method can be used to solve Structural
Optimization problems with a simple compliance objective that uses a volume or mass
constraint.

Note:

The following support limitations apply to the Optimality Criteria

method:

– Only supports the Compliance (Structural) setting for the Re-

sponse Type column of the Objective object worksheet.

– Only Volume and Mass constraints are supported.

See the Optimization Solver Methods (p. 170) section for additional technical details
about this solver type.

Analysis Data Management Category

See the Analysis Data Management Category section of the Help for additional information
about the properties of this category.

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 Specify Analysis Settings

Shape Optimization

For the Shape Optimization method, you can modify the properties as described below.

Definition Category

The Definition category of the Analysis Settings is only available when performing a Struc-
tural Optimization analysis. The properties of the Definition category include:

• Maximum Number of Iterations: This property specifies the maximum number of iter-
ations performed for the Structural Optimization analysis. The solution process continues
until the application achieves convergence accuracy or reaches the maximum number
of iterations. The default value is 500.

• Convergence Accuracy: This property specifies the convergence criteria of the Struc-
tural Optimization analysis. The solution process continues until the application achieves
convergence accuracy or reaches the maximum number of iterations. The default value
is 0.1%.

Output Controls

The properties of the Output Controls category include:

• Export Design Properties. This property is only available for a Structural Optimization
analysis when you have an upstream Modal, Static Structural, or Thermal analysis system.
Upstream Harmonic Response analyses do not support the export of structural results.
You use the options when the application creates solution data. You can then create
results in your Structural Optimization analysis that correspond to your upstream ana-
lysis. These results enable you to examine the mechanical behavior of your optimal
design (corresponding to the last accepted iteration) as well as the mechanical behavior
of intermediate designs. Property options include:

– No (default): No solution data is generated.

– On Final Design: Solution data is created at the end of the optimization process.
This corresponds to the last accepted iteration (optimal design).

– All Accepted Iterations: Solution data is generated after each accepted iteration of
the optimization process. That is, the solution data includes all accepted iterations.

– Last Accepted Iteration: Solution data is generated during the optimization process
that corresponds to the last accepted iteration. That is, the single data is updated
during the optimization in accordance with the latest accepted design.

Export Design Properties File Format: This property displays when you specify
the Export Design Properties property. Options include HDF5 File (default) and
VTK File (requires external reader).

Note:

These structural results are displayed on a triangle-based surface-mesh.

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Optimization Analysis Workflow

• Store Results At: Based on the analysis type, specify this time to be All Time Points
or All Iterations (default setting), Last Time Point or Last Iteration, Equally Spaced
Points or Specified Recurrence Rate.

Value. Displayed only if Store Results At is set to Equally Spaced Points or Spe-
cified Recurrence Rate.

See Output Controls section for additional information about the properties of this category.

Analysis Data Management Category

See the Analysis Data Management Category section of the Help for additional information
about the properties of this category.

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 Specify Analysis Settings

Mixable Density Based Optimization

For the Topology Optimization - Mixable Density method, you can modify the properties as
described below.

Definition Category

The Definition category of the Analysis Settings is only available when performing a Struc-
tural Optimization analysis. The properties of the Definition category include:

• Maximum Number of Iterations: This property specifies the maximum number of iter-
ations performed for the Structural Optimization analysis. The solution process continues
until the application achieves convergence accuracy or reaches the maximum number
of iterations. The default value is 500.

• Convergence Accuracy: This property specifies the convergence criteria of the Struc-
tural Optimization analysis. The solution process continues until the application achieves
convergence accuracy or reaches the maximum number of iterations. The default value
is 0.1%.

Output Controls

The properties of the Output Controls category include:

• Export Design Properties. This property is only available for a Structural Optimization
analysis when you have an upstream Modal, Static Structural, or Thermal analysis system.
Upstream Harmonic Response analyses do not support the export of structural results.
You use the options when the application creates solution data. You can then create
results in your Structural Optimization analysis that correspond to your upstream ana-
lysis. These results enable you to examine the mechanical behavior of your optimal
design (corresponding to the last accepted iteration) as well as the mechanical behavior
of intermediate designs. Property options include:

– No (default): No solution data is generated.

– On Final Design: Solution data is created at the end of the optimization process.
This corresponds to the last accepted iteration (optimal design).

– All Accepted Iterations: Solution data is generated after each accepted iteration of
the optimization process. That is, the solution data includes all accepted iterations.

– Last Accepted Iteration: Solution data is generated during the optimization process
that corresponds to the last accepted iteration. That is, the single data is updated
during the optimization in accordance with the latest accepted design.

Export Design Properties File Format: This property displays when you specify
the Export Design Properties property. Options include HDF5 File (default) and
VTK File (requires external reader).

Note:

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Optimization Analysis Workflow

These structural results are displayed on a triangle-based surface-mesh.

• Store Results At: Based on the analysis type, specify this time to be All Time Points
or All Iterations (default setting), Last Time Point or Last Iteration, Equally Spaced
Points or Specified Recurrence Rate.

Value. Displayed only if Store Results At is set to Equally Spaced Points or Spe-
cified Recurrence Rate.

See Output Controls section for additional information about the properties of this category.

Analysis Data Management Category

See the Analysis Data Management Category section of the Help for additional information
about the properties of this category.

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 Specify Analysis Settings

Topography Optimization

For the Topography Optimization method, you can modify the properties as described below.

Definition Category

The Definition category of the Analysis Settings is only available when performing a Struc-
tural Optimization analysis. The properties of the Definition category include:

• Maximum Number of Iterations: This property specifies the maximum number of iter-
ations performed for the Structural Optimization analysis. The solution process continues
until the application achieves convergence accuracy or reaches the maximum number
of iterations. The default value is 500.

• Convergence Accuracy: This property specifies the convergence criteria of the Struc-
tural Optimization analysis. The solution process continues until the application achieves
convergence accuracy or reaches the maximum number of iterations. The default value
is 0.1%.

Output Controls

The properties of the Output Controls category include:

• Export Design Properties. This property is only available for a Structural Optimization
analysis when you have an upstream Modal, Static Structural, or Thermal analysis system.
Upstream Harmonic Response analyses do not support the export of structural results.
You use the options when the application creates solution data. You can then create
results in your Structural Optimization analysis that correspond to your upstream ana-
lysis. These results enable you to examine the mechanical behavior of your optimal
design (corresponding to the last accepted iteration) as well as the mechanical behavior
of intermediate designs. Property options include:

– No (default): No solution data is generated.

– On Final Design: Solution data is created at the end of the optimization process.
This corresponds to the last accepted iteration (optimal design).

– All Accepted Iterations: Solution data is generated after each accepted iteration of
the optimization process. That is, the solution data includes all accepted iterations.

– Last Accepted Iteration: Solution data is generated during the optimization process
that corresponds to the last accepted iteration. That is, the single data is updated
during the optimization in accordance with the latest accepted design.

Export Design Properties File Format: This property displays when you specify
the Export Design Properties property. Options include HDF5 File (default) and
VTK File (requires external reader).

Note:

These structural results are displayed on a triangle-based surface-mesh.

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Optimization Analysis Workflow

• Store Results At: Based on the analysis type, specify this time to be All Time Points
or All Iterations (default setting), Last Time Point or Last Iteration, Equally Spaced
Points or Specified Recurrence Rate.

Value. Displayed only if Store Results At is set to Equally Spaced Points or Spe-
cified Recurrence Rate.

See Output Controls section for additional information about the properties of this category.

Analysis Data Management Category

See the Analysis Data Management Category section of the Help for additional information
about the properties of this category.

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 Specify Analysis Settings

Materials Optimization

For the Materials Optimization method, you can modify the properties as described below.

Definition Category

The Definition category of the Analysis Settings is only available when performing a Struc-
tural Optimization analysis. The properties of the Definition category include:

• Maximum Number of Iterations: This property specifies the maximum number of iter-
ations performed for the Structural Optimization analysis. The solution process continues
until the application achieves convergence accuracy or reaches the maximum number
of iterations. The default value is 500.

• Convergence Accuracy: This property specifies the convergence criteria of the Struc-
tural Optimization analysis. The solution process continues until the application achieves
convergence accuracy or reaches the maximum number of iterations. The default value
is 0.1%.

Output Controls

The properties of the Output Controls category include:

• Export Design Properties. This property is only available for a Structural Optimization
analysis when you have an upstream Modal, Static Structural, or Thermal analysis system.
Upstream Harmonic Response analyses do not support the export of structural results. You
use the options when the application creates solution data. You can then create results in
your Structural Optimization analysis that correspond to your upstream analysis. These results
enable you to examine the mechanical behavior of your optimal design (corresponding to
the last accepted iteration) as well as the mechanical behavior of intermediate designs.
Property options include:

– No (default): No solution data is generated.

– On Final Design: Solution data is created at the end of the optimization process. This
corresponds to the last accepted iteration (optimal design).

– All Accepted Iterations: Solution data is generated after each accepted iteration of the
optimization process. That is, the solution data includes all accepted iterations.

– Last Accepted Iteration: Solution data is generated during the optimization process that
corresponds to the last accepted iteration. That is, the single data is updated during the
optimization in accordance with the latest accepted design.

Export Design Properties File Format: This property displays when you specify the
Export Design Properties property. Options include HDF5 File (default) and VTK File
(requires external reader).

Important:

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Optimization Analysis Workflow

Strain-based results are not supported for the Topology Optimization - Density
Based method.

Note:

These structural results are displayed on a triangle-based surface-mesh.

• Store Results At: Based on the analysis type, specify this time to be All Time Points or All
Iterations (default setting), Last Time Point or Last Iteration, Equally Spaced Points or
Specified Recurrence Rate.

Value. Displayed only if Store Results At is set to Equally Spaced Points or Specified
Recurrence Rate.

See Output Controls section for additional information about the properties of this category.

Analysis Data Management Category

See the Analysis Data Management Category section of the Help for additional information
about the properties of this category.

2.5. Define Optimization Method and Regions

You use the Optimization Region object to specify the optimization method you want to use and then
select the regions of your geometry on which to perform optimization. Using the properties of the object,
you define the Design Region and the Exclusion Region for the analysis. Refer to the Optimization
Region object reference page for additional information about this object.

Go to a section topic:

• Select the Optimization Type (p. 44)

• Create Multiple Optimization Regions (p. 45)

• Specify Object Properties (p. 46)

• Define Additional Restriction Regions (p. 49)

Select the Optimization Type

You use the Optimization Type property to select the desired optimization method.

Optimization Type Property Options

• Topology Optimization - Mixable Density (default)

• Topology Optimization - Level Set Based

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 Define Optimization Method and Regions

• Lattice Optimization

• Shape Optimization

• Topography Optimization

• Materials Optimization

• Topology Optimization - Density Based

See the Design Method Definitions (p. 123) section for more information about the requirements
and limitations of each method.

Design Region Property

The properties of the Design Region category enable you to define the geometry as a Geometry
Selection or a Named Selection. This is the region that you wish to optimize.

Exclusion Region Property

The properties of the Exclusion Region category enable you to specify a region (geometric entities
or elements) to be excluded from optimization. You specify excluded regions using defined
Boundary Conditions, Geometry Selection, or a Named Selection.

Note:

Currently, the application does not provide an option to exclude contact and target en-
tities. If you are using either the Shape Optimization or Topography methods and your
model includes bodies with contact conditions, Ansys recommends that you apply a
Local Design Restriction to these entities using the Non-Optimizable setting. See the
Define Additional Restriction Regions (p. 49) topic below.

Create Multiple Optimization Regions

Except for the Materials Optimization method, you can specify multiple Optimization Regions objects
and mix the level set, mixable density, shape optimization, and topography methods together. When
mixing the use of these methods, you can define as many Optimization Region objects as needed and
attach individual manufacturing constraints to each.

Density Based optimization regions cannot be mixed with other types of optimization regions. When
you are using the density-based optimization method you have two options: you can use multiple
Optimization Region objects or you can use Geometry Selection or Named Selections to define the
scope of the Manufacturing Constraints.

Important:

• Each optimization region must be uniquely scoped. The scoping of the regions cannot
overlap. The application will include all the geometries of the optimization regions in the
optimization process. You can use the individual optimization regions for the scoping of
geometric response constraints and of manufacturing constraints.

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Optimization Analysis Workflow

• The Mixable Density, Level Set, and Shape Optimization options/methods only support
3D solid elements and the Topography Optimization method only supports shell elements.

When Beta Options are active, the Mixable Density method also supports 2D solid and
3D shell elements.

• When using the Materials Optimization method, only one Optimization Region object
can be specified in the analysis.

The following table outlines the methods that you can combine within an optimization problem.

Density Lattice Level Set Mixable Shape Topography

Based Optimization Based Density Optimization Optimization
Optimization Optimization
Density Based X
Optimization
Lattice Optimization X
Level Set Based X X X X
Optimization
Mixable Density X X X X
Shape Optimization X X X X
Topography X X X X
Optimization

Specify Object Properties

Using the properties of the Details pane, specify the method optimization regions for your analysis.

Category Properties/Options/Description
Design Scoping Method. The options for this property include:
Re-
gion • Geometry Selection (default): This option indicates that the design region is applied
to a geometry or geometries, which are chosen using graphical selection tools.
When you specify Geometry Selection for the Scoping Method, the Geometry
property will appear.

In this case, use selection filters on the Graphics Toolbar to pick your geometric
entities (only body and element selection), and then click Apply. Once complete,
the property displays the type of geometry (Body, Element, etc.) and the number
of selected geometric entities (for example: 1 Body, 12 Elements).

• Named Selection: Indicates that the geometry selection is defined by a Named

Selection. When you specify Named Selection for the Scoping Method, the Named
Selection property will appear. This property provides a drop-down list of available
user-defined Named Selections (only body-based and element-based Named
Selections are supported).

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 Define Optimization Method and Regions

Category Properties/Options/Description
Ex- Defined By. The options for this property include:
clu-
sion • Boundary Condition (default):
Re-
gion When you specify Boundary Condition for the Defined By property, a Boundary
Condition property will appear. This property includes the following options:

– All Boundary Conditions: Applies the locations of all loading conditions

and supports from the upstream static/modal system.

– All Loads: Applies the locations of all loading conditions from the upstream
static/modal system.

– All Supports: Applies the locations of all supports from the upstream
static/modal system.

– None: No boundary condition locations are applied.

Note:

Ansys strongly recommends that, at a minimum, you specify the option

All Loads for any Exclusion Region.

• Geometry Selection: This option indicates that the design region is applied to a
geometry or geometries, which are chosen using graphical selection tools. When
you specify Geometry Selection for the Scoping Method, the Geometry property
will appear. Exclusion Region geometry selections can be scoped to bodies, faces,
edges, and elements.

• Named Selection: Indicates that the geometry selection is defined by a Named

Selection. When you specify Named Selection for the Scoping Method, the Named
Selection property will appear. This property provides a drop-down list of available
user-defined Named Selections. Exclusion Region Named Selections support body-,
face-, edge-, and element-based Named Selections.

Exclusion Thickness: This property displays when you set the Optimization Type property
to Topology Optimization - Level Set Based or Topology Optimization - Mixable
Density. The default setting for this property is Program Controlled or you can enter a
value manually. This option enables you to specify a thickness for the Exclusion Region.
The default value is two times the average element size. The unit must be a length.

Exclusion Extension: This property displays when you set the Optimization Type property
to either Topology Optimization - Level Set Based or toTopology Optimization - Mixable
Density. This option enables you to specify the extension type for the Exclusion Region.
Options include is Isotropic (default) and Orthotropic. Use the Isotropic option to perform
expansion uniformly in the three directions. Use the Orthotropic option to perform the
expansion along the surface normal. The Orthotropic option is only available for surface
bodies.

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Optimization Analysis Workflow

Category Properties/Options/Description
Op- Optimization Type: You use this property to specify the type of optimization you wish
tim- to perform. Options include:
iz-
a- • Topology Optimization - Density Based
tion
Op- • Topology Optimization - Level Set Based
tion
• Lattice Optimization (see below)

• Shape Optimization (see below)

• Topography Optimization (see below)

• Materials Optimization

• Topology Optimization - Mixable Density

Lattice Optimization

The following additional properties are available when you select Lattice Optimization
as the Optimization Type:

• Lattice Type: This property specifies the structure of the unit cell.

• Minimum Density: This property specifies a minimum density in order to avoid

lattice structures that are too thin.

• Maximum Density:This property specifies a maximum density. The element

will be considered as full for densities higher than the Maximum Density.

• Lattice Cell Size: The value of this property specifies the lattice cell size to be
used when rebuilding the lattice geometry for printing.

Shape Optimization and Topography Optimization

The following additional properties are available when you select Shape Optimization
or Topography Optimization as the Optimization Type:

• Move Limit Per Iteration: This property enables you to define how far each
node can move at each iteration. It must be defined in length units, for example
one element size. By default, this property is set to Program Controlled. Select
the Manual option to change the value.

• Total Move Limit: This property enables you to define how far each node can
move in total. It must be defined in length units, for example three times the
element size. By default, this property is set to Program Controlled. Select the
Manual option to change the value.

• Mesh Deformation Control: This property enables you to define how much
the mesh can be stretched. It is an additional control to avoid element distortion.
This unit-less value is a sort of penalty factor that ranges from 0 (no control)
to 1.0. By default, this property is set to Program Controlled. Select the Manual
option to change the value.

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 Define Optimization Method and Regions

Define Additional Restriction Regions

To preserve critical geometry, use the Local Design Restriction object to specify additional design regions
on your model.. This object is inserted as a child object of the Optimization Region object. The recom-
mended use of the Local Design Restriction object includes scenarios wherein certain regions of interest,
that may be disconnected, need to be retained even though no loads or boundary conditions exist on
the region.

Application
1. From the Optimization Region object, add the object using the context (right-click) menu option
Insert > Local Design Restriction or select the Local Design Restriction option on the
Environment Context tab.

2. Using the Defined By and Geometry/Named Selection properties, specify additional design
restrictions on geometric entities or geometry- or element-based Named Selections. Restrictions
apply based on the setting of the Type property described below.

3. Use the Type property to define the additional exclusion restrictions. Options include:

• Non-Optimizable (default): The application does not optimize the selected regions (the degrees
of freedom). For the topology optimization methods this means the selection will have forced
material. For Shape Optimization or Topography methods, this means that the nodes cannot
be moved. For the Materials Optimization method, a Materials property displays. Specify a
material for the selected regions.

• In-Plane Morphing: Supported for the Shape Optimization method and face selections only,
the application does not move any nodes vertically with respect to the original face. That is,
the nodes remain "in the plane." See the Displacement Illustration (p. 50) below.

Shape Optimization and Topography Methods Only

The options listed below are available for the Shape Optimization and Topography methods.
Except for the Along Direction Morphing option, all options only support face-based scoping,
either through direct selection or using a Named Selection.

• Along Direction Morphing: The application only displaces the nodes of the specified
selection along a defined coordinate direction. See the Displacement Illustration (p. 50)
below.

• Along Normal Morphing: Nodes of the selection can only be displaced along the initial
normal of the surface. See the Displacement Illustration (p. 50) below.

• Free: The application can displace nodes in any direction up to the distance specified by
the Total Move Limit property. See the Node Movement Illustration (p. 51) below.

• Inward Morphing[a]: The application can only displace nodes inward up to the limit specified
by the Total Move Limit property. See the Node Movement Illustration (p. 51) below.

• Outward Morphing[a]: The application can only displace nodes outward up to the limit
specified by the Total Move Limit property. See the Node Movement Illustration (p. 51)
below.

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Optimization Analysis Workflow

Application
4. Based on the Type property setting, specify:

• A Coordinate System and Axis for the allowed displacement (Location and Orientation
category).

Or...

• The Total Move Limit property of the Optimization Option category. This value, either
determined by the application or entered manually, defines the maximum distance a node
can move.

Note:

If your simulation includes Symmetry, you must scope the Local Design Restriction object
to each side of the symmetrical body so that the application respects the symmetry and
correctly processes the exclusion.

[a]
[a]
Inward/Outward Directions
For the Shape Optimization method, inward and outward refer to the interior/exterior of the initial body. For the Topography
Optimization method, because the Optimization Region is not a solid body, inward and outward refer to the corresponding
sides of your selection. The green highlight of the selected face indicates the outward side.

Displacement Illustration
For the mesh nodes illustrated in red:

• The black coordinate shows no local constraint specified. The node can move in any of the three
directions.

• The pink directions show the displacement for the In-Plane Morphing option. The node can
only move on the original surface.

• The green directions show the displacement for the Along Direction Morphing option. The
node can only move along the direction you specify.

• The blue directions show the displacement for the Along Normal Morphing option. The node
can only move along the normal of the original surface.

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 Define Optimization Method and Regions

Node Movement Illustration

The area created by nodes movements for the various settings are illustrated bellow:

Free setting with a large value specified for the Total Move Limit.

inward Morphing setting with a moderate value specified for the Total Move Limit.

Outward Morphing setting with large value specified for the Total Move Limit.

Free setting with moderate value specified for the Total Move Limit.

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Optimization Analysis Workflow

2.6. Determine Objective and Constraints Capabilities

Objective and Response Constraint Capability Map

The options for the Objective and Response Constraint object depend upon the analysis you are op-
timizing, the response constraint you want to specify, and the optimization method you are using. Review
the following table to see which Objective and Response Constraint objects are available for each
method, noting the following:

• Constraint/Objective (C/O): Supported as Response Constraint and Objective.

• C: Supported as a Response Constraint only.

• O: Supported as a Objective only.

Upstream Level
Density Lattice Shape Mixable
Analysis Response Set Topography Materials
Based Optimization Optimization Density
System? Based
Geometric Y Y Y Y Y Y Y
(default) Mass/Volume [a]
C/O C/O C/O C/O C/O C/O C/O

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 Determine Objective and Constraints Capabilities

Upstream Level
Density Lattice Shape Mixable
Analysis Response Set Topography Materials
Based Optimization Optimization Density
System? Based
Center of C
C C C C C
Gravity[a]
Moment of C C
C C C C
Inertia[a]
User Defined C/O C/O C/O
C/O C/O
Criterion

Harmonic Upstream
Re- analysis No No Yes Yes Yes Yes
sponse[b] supported?
User-defined
C/O C/O C/O C/O
Criterion (p. 3)

Static Upstream Yes

Structural analysis Yes Yes Yes Yes Yes Yes
System supported?
Compliance[c] C/O C/O C/O C/O C/O C/O C/O
[a]
Displacement C C C C
Stress C/O C/O C/O C/O C/O
Local Stress C
Reaction
C C C
Force[a]
User-defined
C/O C/O C/O C/O C/O C/O
Criterion (p. 3)

Nonlinear Upstream No
Yes
Static analysis No No Yes No
(Beta)
Structural supported?
System - Compliance C/O
(Nonlinear
Contact Displacement C
only) [d] Stress C/O
Local Stress C
Reaction Force C
User-defined
Criterion (p. 3)
Accumulated
Plastic Strain O
(APS)

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Optimization Analysis Workflow

Upstream Level
Density Lattice Shape Mixable
Analysis Response Set Topography Materials
Based Optimization Optimization Density
System? Based
Nonlinear Upstream
Static analysis No No No Yes No
Structural supported?
[d]
Accumulated
Plastic Strain O
(APS)

Modal Upstream
analysis Yes Yes Yes Yes Yes Yes
supported?
Frequency[a] C/O C/O C/O C/O
User-defined
C/O C/O C/O C/O
Criterion (p. 3)[e]

Steady-State Upstream Yes

Thermal analysis Yes No Yes Yes No
System supported?
Thermal C/O
O C/O C/O
Compliance
Temperature[a] C
User-defined
C/O C/O C/O
Criterion (p. 3)

Nonlinear Upstream
Steady-State analysis Yes No No No No No
Thermal supported?
System Thermal
(Radiation O
Compliance
Only)
Temperature C
[a] This response will be deprecated in a future release. Ansys recommends that you use a
User Defined Criterion response instead as it is more versatile.
[b] The Structural Optimization analysis only supports an upstream standalone MSUP Harmonic
Response analysis.
[c] The application ignores Condensed Part objects included in the model when computing
compliance.
[d] To specify a nonlinear analysis, set Large Deflection property to On in the Details of the
Solver Controls category of the Analysis Settings.
[e] If Beta Options are active, Modal analyses support User Defined Criteria when you also in-
clude a Cyclic Region or a Pre-Meshed Cyclic Region object. Mode Tracking is not supported
for the Robust Frequencies setting.

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 Define Design Objectives

2.7. Define Design Objectives

An Objective object is added by default for optimization systems. This object displays the Worksheet
in order for you to specify the optimization goal.

Go to a section topic:

• Application (p. 55)

• Objective Worksheet Overview (p. 55)

• Objective Worksheet Properties (p. 57)

Application
To apply an Objective object: On the Environment Context tab: select Objective, or right-click the
Environment tree object or in the Geometry window and select Insert > Objective.

Objective Worksheet Overview

When you select the Objective object, the Worksheet displays by default, as illustrated in the images
shown below. You use the Worksheet to specify Response Type, Formulation, Goal, and Weights for
the steps/modes of the upstream analysis. A Structural Optimization analysis supports one or more
upstream Harmonic Response, Modal, Static Structural, or Steady-State Thermal analyses. For the
Shape Optimization method, nonlinear Static Structural analyses are also supported.

Whenever you link a Harmonic Response, Modal, Static Structural, or Steady-State Thermal analysis
to a Structural Optimization analysis in the Project Schematic, a new row is added to the Worksheet.
The default Response Type setting for a Static Structural analysis is Compliance, for a Modal analysis
it is Frequency, and for a Steady-State Thermal analysis it is Thermal Compliance. There is not default
setting for a Harmonic Response analysis.

Single Static Structural System

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Optimization Analysis Workflow

Single Modal System

Single Thermal System

You can insert additional rows into the Worksheet to specify multiple response types for multiple systems
and Weight values for a single step or multiple steps (by disabling or enabling the Multiple Sets option).

Note:

For the Topology Optimization - Density Based method, Objective objects of different
types are always normalized. Here, the option only applies for Objective objects of same
type.
For the Topology Optimization - Level Set method, when you have multiple Objective
objects specified, you can choose to normalize them with their initial response to give
equal weightage for all objectives. To do so, set the Normalized Sum property to Yes.

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 Define Design Objectives

Multiple Systems

Worksheet Properties
You set the values for properties in the Worksheet columns to define the Objective object as follows:

Enabled

This option is checked by default. When checked the application includes the specifications of the
row in the solution. Unchecking the row excludes it from the solution.

Response Type

The options for this column depend upon the analysis you are optimizing. Supported options include:

• Mass/Volume

• Stress

• Compliance

• Criterion (p. 3)

• Accumulated Plastic Strain

• Frequency

• Thermal Compliance

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Optimization Analysis Workflow

Review the Objective and Response Constraint Capability Map (p. 52) for a complete listing of the
supported analysis types, response constraint you want to specify, and the optimization method
you are using.

Note:

When you select a criterion that is scoped to Remote Point or remote boundary condition
(Remote Force or Remote Displacement), the Base Result property options Reaction
Force and Reaction Moment are not supported for the Density Based and Lattice Op-
timization methods.

Goal

The options for this property depend upon the selection made in the Response Type column.

If constraint is... Then this entry can be set to...

Mass/Volume Minimize.

Stress

Accumulated Plastic
Strain
Frequency Maximize.
Criterion Minimize or Maximize[a].
Compliance
Thermal Compliance Minimize or Maximize.
[a] Maximization of Compliance is not supported for the Density Based method.

Note:

Generally, you set static and thermal compliance constraints to Minimize, however, the
application also supports the Maximize setting.

Formulation

This column is applicable only when the Response Type is set to Compliance (Static Structural
analysis), Stress (Static Structural analysis), or Thermal Compliance (Steady-State Thermal Analysis).

Compliance

For the Density Based optimization method, when you select Compliance (Static Structural
analysis), this column is used to specify the formulation method by which maximum stiffness
can be attained to minimize the compliance.

• Program Controlled: This default setting selects either the Force or Displacement for-
mulation based on whether a force load or a displacement load exists in the Static
Structural analysis.

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 Define Design Objectives

• Force: If you have not applied a displacement load and a force load is applied, then the
displacement, with respect to this force load, is minimized during the optimization.

• Displacement: If you have a non-zero displacement load and no force load is applied,
then the force that leads to the given displacement is maximized during the optimization.

Note:

For the Topology Optimization - Level Set Based and Shape Optimization
methods, the Compliance option uses a unique formula regardless of the
context. That is, it executes in the presence of surface loads, acceleration,
prescribed displacement, and/or thermal expansion.

Stress

When Stress is the specified Response Type, Formulation options include:

• Equivalent von-Mises Stress (default). This option is supported for density based, level set,
and shape optimization methods.

• Local Equivalent von-Mises Stress. This option is only supported for shape optimization
methods.

• Maximum Principal Stress. This option is supported for density based, level set, and shape
optimization methods.

• Local Strain Energy. This option is supported for level set and shape optimization methods.

The strain energy computed only over the optimization region of interest.

Important:

The Local Strain Energy calculation is exactly twice the Compliance if, and only
if:

1. Local Strain Energy is computed over the entire model, and,

2. There are only loads in the upstream structural analysis.

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Optimization Analysis Workflow

As a result, Ansys recommends that you keep this in mind when specifying this
stress option. For example, if you apply a prescribed-displacement and minimize
the Local Strain Energy, you could experience an unwanted (but expected) dis-
connection.

While the Local Strain Energy is by nature, a scalar value, the Equivalent von-
Mises Stress and Maximum Principal Stress options are elemental scalar-fields.
Before being consumed by the optimizer, those two stress-norm are scalarized in
a way to mimic the maximum and to stay derivable.

As summarized below, the application monitors all elements of the optimization region, however,
based on the method and criterion, some elements may be ignored. This table describes the
supported methods only.

Methods
Criterion Density Based Level Set Based Shape Optimization
Equivalent Scoping elements: All Scoping elements: All Scoping elements: All.
von-Mises Stress elements except those elements except those
lying in the Exclusion lying in the Exclusion
Region. Region.
Local Equivalent Not Available Not Available Scoping elements: All
von-Mises Stress elements except those
lying in the Exclusion
Region.
Maximum Scoping elements: All Scoping elements: All Scoping elements: All.
Principal Stress elements except those elements except those
lying in the Exclusion lying in the Exclusion
Region. Region.
Local Strain Not Available Not Available Scoping elements: All.
Energy

Thermal Compliance

For Thermal Compliance, this column is used to specify the formulation method by which heat
transfer is maximized. Options include Program Controlled (default), Thermal Load, and
Temperature. The Thermal Load option includes all thermal loads (Convection, Heat Flux, etc.)
exceptTemperature. For this Worksheet property, note the following behaviors:

• Program Controlled: This default setting selects either the Temperature or Thermal
Load formulation based on whether a temperature load or a thermal load exists in the
Steady-State Thermal analysis.

• Thermal Load: If you have not applied a Temperature load and a Thermal Load is applied,
then the average temperature, with respect to this thermal load, is minimized during the
optimization.

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 Define Design Objectives

• Temperature: If you have Temperature load and no Thermal Load is applied, then the
thermal load that leads to the given temperature is maximized during the optimization.

Note:

For the Topology Optimization - Level Set Based and Shape Optimization
methods, the Thermal Compliance option uses a unique formula regardless
of the context. That is, it executes in the presence of Heat Flux, Heat Flow,
prescribed Displacement, Convection conditions, and/or Internal Heat Gener-
ation.

Environment Name

From the drop-down list, select the environment associated with the entries of the Response Type
and Goal properties. Note that geometric criteria (mass, volume, etc) does not need to be associated
to an environment.

Criterion

From the drop-down list, select the desired criterion.

Weight

The default value for this option is 1. The Weight can be any real number.

If you define multiple responses, they are aggregated into a weighted sum, using:

Where:

is the design of the kth iteration.

is the ith Objective response.

is the effective weight of the ith Object response.

is the aggregated Objective.

When the Normalized Sum option is set to No, then , where is the entered weight.

When the Normalized Sum option is set to Yes, then . This indicates that it is scaled

using the value at the first iteration.

Multiple Sets

The values for this option are Enabled (default) or Disabled.

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Optimization Analysis Workflow

• If Enabled, you can specify Start Step and End Step values within the boundaries of the maximum
number of steps defined in the upstream Static Structural analysis.

• If Disabled, only the Step column is available to define the Weight for a single step.

Start Step

This option is available when the Environment Name column is set to either Static Structural or
Steady-State Thermal. This option requires the Multiple Sets option to be set to Enabled in order
to define the Start Step from the upstream solution.

End Step

This option is available when the Environment Name column is set to either Static Structural or
Steady-State Thermal. This option requires the Multiple Sets option to be set to Enabled in order
to define the End Step from the upstream solution.

Step

This option is supported when the Environment Name column is set to either Static Structural
or Steady-State Thermal. This option specifies the step number used from the upstream solution.
This field is read-only when the Multiple Sets option is set to Enabled, and the entry for this option
can also be Multiple or All, if the Start and End Step values cover more than one step or the entire
analysis from the upstream solution. Otherwise, you can specify the weight for single steps using
this option.

Start Mode

Only supported when Modal system is selected in the Environment Name column. This field requires
the Multiple Sets option to be set to Enabled in order to define the Start Mode for the selected
Modal analysis solution.

End Mode

Only supported when Modal system is selected in the Environment Name column. This field requires
the Multiple Sets option to be set to Enabled in order to define the Start Mode for the selected
Modal analysis solution.

Mode

Only supported when Modal system is selected in the Environment Name column. This option
specifies the mode number used from the upstream solution. This field is read-only when the Multiple
Sets option is set to Enabled and the entry for this option can also be Multiple or All, if the Start
Mode and End Mode values cover more than one mode or all of the modes from the upstream
solution. Otherwise, you can specify the weight for single modes using this option.

Refer to the Objective object reference page for additional information.

2.8. Define Response Constraints

The Structural Optimization analysis requires and automatically inserts a response constraint. The
available response types include:

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 Define Response Constraints

• Volume Constraint

• Mass Constraint (default)

• Center of Gravity Constraint

• Moment of Inertia

• Compliance Constraint (Static Structural)

• Displacement Constraint (Static Structural)

• Reaction Force Constraint (Static Structural)

• Global Stress Constraint (Static Structural)

• Local von-Mises Stress Constraint (Static Structural)

• Natural Frequency Constraint (Modal)

• Thermal Compliance Constraint (Steady-State Thermal)

• Temperature Constraint (Steady-State Thermal)

• Criterion Constraint (p. 3) (Harmonic Response, Modal, Static Structural, Steady-State Thermal)

Note:

Shell Body Stress Constraints

When you apply a Global Stress Constraint or a Local von-Mises Stress Constraint
to a shell body, the application optimizes the body using the elemental mean of the
top and bottom surfaces.

Note:

Review the Objective and Response Constraint Capability Map (p. 52) for a complete listing
of the supported analysis types, response constraint you want to specify, and the optimization
method you are using.

Application
To apply a Response Constraint:

1. On the Environment Context tab, open the Response Constraint drop-down menu and select
the desired response constraint, or, right-click the Environment (Structural Optimization)
object or in the Geometry window and select Insert>[desired Response Constraint menu
option].

2. The application inserts the appropriate object matching the selected response option.

Additional properties display based on the setting of the Response property setting, and include:

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Optimization Analysis Workflow

Geometric-Based Analyses

• Mass Constraint/Volume Constraint: Based on how you define the constraint,

modify the percentage or the value as needed.

• Center of Gravity Constraint: Specify the upper and/or the lower limit (Max-
imum Value/Minimum Value) and desired Axis.

• Moment of Inertia Constraint: Based on how you define the constraint,

modify the percentage or the value as needed and specify a desired Coordinate
System and Axis.

• Criterion Constraint: Specify the Criterion, Lower Bound, and Upper Bound
properties.

Harmonic Response Analyses

Criterion Constraint: Specify the Criterion, Lower Bound, and Upper Bound properties.

Modal Analyses

• Natural Frequency Constraint: Specify the values for the Mode Number, Minimum
Frequency, and Maximum Frequency properties. Modify the Environment Selection
property as needed.

• Criterion Constraint: Specify the Criterion, Lower Bound, and Upper Bound
properties.

Static Structural Analyses

• Global Stress Constraint: Specify a Stress Type, either Equivalent von-Mises Stress
(default), Local Equivalent von-Mises Stress, Maximum Principal Stress, or Local
Strain Energy, and the Maximum stress value. Modify the Environment Selection
property as needed.

• Local von-Mises Stress Constraint: Define the Scoping Method as either Geometry
Selection or Named Selection and then specify the geometry. Also specify the
Maximum stress value. Modify the Environment Selection property as needed.

• Displacement Constraint: Specify the X/Y/Z Component (Max) properties. Modify

the Environment Selection property as needed.

• Reaction Force Constraint: Specify the Axis Selection, Criteria, Bound Type, and
X/Y/Z Component properties. Modify the Environment Selection property as
needed.

• Compliance: Specify the maximum value. Modify the Environment Selection

property as needed.

• Criterion Constraint: Specify the Criterion, Lower Bound, and Upper Bound
properties.

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 Define Response Constraints

Thermal Analyses

• Temperature Constraint: Specify the Temperature (Abs Max) property. Modify the
Environment Selection property as needed.

• Thermal Compliance: Specify the maximum value. Modify the Environment Selec-
tion property as needed.

• Criterion Constraint: Specify the Criterion, Lower Bound, and Upper Bound prop-
erties.

Note:

Where applicable, the application automatically specifies a (read-only) Coordinate

System property.

Renaming Based on Definition

The Response Constraint object provides the context menu (right-click) option Rename Based on
Definition. This option automatically renames the object based on your Response property selection.
That is, it renames the object "Mass Constraint,""Volume Constraint,""Global Stress Constraint," or
"Natural Frequency Constraint" accordingly. This feature supports all of the options of the Response
property.

Details View Properties

The Details view for this object includes the following properties.

Category Properties/Options/Description
Scope Scoping Method: The option for this property is based upon the type of Response
Constraint you specify.

For the Mass Constraint, Volume Constraint, Center of Gravity, and Moment
of Inertia response types, the available Scoping Method options include:

• Geometry Selection: This option indicates that the design region is applied
to a geometry or geometries (body selection only), which are chosen using
the graphical selection tools. When you specify Geometry Selection for
the Scoping Method, the Geometry property displays.

In this case, use selection filters on the Graphics Toolbar to pick your
geometric entities, and then click Apply. Once complete, the property
displays the type of geometry and the number of selected geometric entities
(for example: 1 Body).

• Named Selection: This option indicates that the design region is applied
to a body-based (only) Named Selection. When you specify Named Selection
for the Scoping Method, the Named Selection property displays. This
property provides a drop-down list of available user-defined Named
Selections.

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Optimization Analysis Workflow

Category Properties/Options/Description
• Optimization Region (default): This option indicates that the design region
is applied to the specified Optimization Region. When Optimization
Region is specified for the Scoping Method, the Optimization Region
Selection property also displays. This property contains a default value:
Optimization Region.

• All Optimization Regions: When you have multiple Optimization Region

objects defined, this option indicates that the constraint is applied to all of
them.

For Local von-Mises Stress Constraint, Displacement Constraint, and Reaction

Force Constraint response types, supported by a linked Static Structural analysis,
and the Temperature Constraint, supported by a linked Steady-State Thermal
analysis, the available options, as described above, include:

• Geometry Selection: Not restricted to body-based scoping only.

• Named Selection: Not restricted to body-based scoping only.

For the Global Stress Constraint (Static Structural only) response type, the only
available option is Optimization Region and All Optimization Regions.

Note:

There is no Scope category for the Natural Frequency Constraint

response type.

Definition Type

This is a read-only property that indicates the object as a Response

Constraint.

Response

The options for this property include:

• Mass (default)/Volume[a]: When you select either of these options,

the Define By property displays. Define By properties include:

– Constant (default): When this option is used, the Percent

to Retain property also displays. The Percent to Retain
property defines the upper bound (in percentage) of the

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 Define Response Constraints

Category Properties/Options/Description
Volume/Mass constraint. The default value is 50. The entry
range for this property is between 1 and 99.

Note:

For the Density Based Optimization method,

this constraint is handled as an equality
constraint.

– Range: When this option is selected, the Percent to Retain

(Min) and Percent to Retain (Max) properties also display.
You use these two properties to define the range, namely
lower and upper bound, in percentage, of the Volume/Mass
constraint. The default value for each is 50. The entry range
for these properties is between 1 and 99.

– Absolute Constant: When selected, the Maximum Value

property also displays. The Maximum Value property defines
the units-based upper bound of the Mass/Volume constraint.
The default value is Free.

Note:

For the Density Based Optimization method,

this constraint is handled as an equality
constraint.

– Absolute Range[a]: When selected, the Minimum Value

and Maximum Value properties also display. You use these
two properties to define the units-based range, namely lower
and upper bound, of the Mass/Volume constraint. The
default value for each is Free.

• Center of Gravity[a]: When this option is selected, the Max Value

and Min Value properties also display and enable you to specify
an upper and lower bound for the constraint. The default value is
Free. You will note a value contained in the field when you select
it. This is a infinite value to indicate a free state.

• Moment of Inertia[a]: When you select this option, the Define By

property displays. Define By properties include:

– Constant (default): When this option is used, the Percent

to Retain property also displays. The Percent to Retain
property defines the upper bound (in percentage) of the
Moment of Inertia. The default value is 50. The entry range
for this property is between 1 and 99.

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Optimization Analysis Workflow

Category Properties/Options/Description
– Range: When this option is selected, the Percent to Retain
(Min) and Percent to Retain (Max) properties also display.
You use these two properties to define the range, namely
the lower and upper bound, in percentage, of the Moment
of Inertia. The default value for each is 50. The entry range
for these properties is between 1 and 99.

– Absolute Constant: Specify the upper bound in the

appropriate Unit system.

– Absolute Range: Specify the upper and lower bound in the

appropriate Unit system.

• Natural Frequency[a]: This option is only available when there is

at least one upstream Modal system. By using this property, the
analysis ensures the specified mode and the range of frequencies
are supported by the optimized body. When selected, the following
associated properties will be shown:

– Mode Number: This property defines the mode number

used to create the optimized body.

– Minimum Frequency: This property defines the minimum

frequency for the selected mode number.

– Maximum Frequency: This property defines the maximum

frequency for the selected mode number.

You can use multiple Natural Frequency objects that specify

different Mode Numbers and corresponding frequency ranges for
each upstream Modal system.

• Global Stress: This option is only available when there is at least

one upstream Static Structural system. You use this property to
make sure that the optimized geometry or structure always supports
a specified maximum stress. When selected, the following
reassociated properties also display:

– Stress Type: Options include Equivalent (Von-Mises) Stress,

Local Equivalent von-Mises Stress, Maximum Principal
Stress, and Local Strain Energy. These options have
optimization method support requirements. See the
Worksheet Properties (p. 57) topic in the Objective (p. 55)
section for more information about the stress options.

– Maximum: Enter a stress value as a Constant or using

Tabular Data entries.

• Local von-Mises Stress: This option is only available when there

is at least one upstream Static Structural system. You use this
property to make sure that the geometry or structure always

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 Define Response Constraints

Category Properties/Options/Description
supports a specified maximum stress using the Maximum property
that also displays when you select the Local von-Mises Stress
option. You specify the stress value of the Maximum property as
either a Constant (default) or using Tabular Data entries (via fly-out
menu). The application supports multiple Local von-Mises Stress
constraints. You can apply this constraint on supported elements
that may or may not be included in the Optimization Region.

• Displacement[a]: This option is only available when there is at least

one upstream Static Structural system. You use this property to
make sure that the optimized geometry or structure always support
a specified maximum displacement using the X/Y/Z Component
(Max) properties that also display when you select the
Displacement option. A read-only Coordinate System property
also displays and is automatically set to Nodal Coordinate System.
You specify the displacement value of the X/Y/Z Component (Max)
properties as either a Constant (default), Free, or using Tabular
Data entries (via fly-out menu). The application supports multiple
Displacement constraints.

Important:

If you apply a Displacement to more than one node,

the absolute value for the constraint is met and negative
numbers are no longer allowed. For example, if you enter
a value of 100N, the constraint is satisfied if it meets a
value between -100 and 100.

• Reaction Force[a]: This option is only available when there is at

least one upstream Static Structural system. You use this constraint
to make sure that the optimized geometry or structure always
support a specified maximum reaction force. The application
supports multiple Reaction Force constraints.

During the solution process, the application calculates a reaction

force for each node used in the Reaction Force constraint (if scoped
to more than one node or a vertex, edge, face, or body). Based on
the Criteria property setting, the reaction forces are either summed
or normalized. Neither of these calculated values can exceed the
entries you make in the Component properties for the specified
direction(s). Reaction Force has the following distinct properties:

– Axis Selection: Options include All (default), X Axis, Y Axis,

and Z Axis.

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Category Properties/Options/Description
– Criteria: Options include Sum (default) and Absolute
Maximum (when scoped to more than one node or a vertex,
edge, face, or body).

Note:

For legacy databases, release 2019 R1 or earlier,

that include Reaction Force constraints, the
default setting for this property is Absolute
Maximum.

– Bound Type: Options include Upper Bound (default) and

Lower Bound.

– X/Y/Z Component (Sum or Max): Component entries are

either Constant or based on Tabular Data entries.

When the Criteria property is set to Sum:

Positive values are treated as upper (maximum)

bounds. Therefore, the constraint is satisfied if the
constraint value is less than the value you specify.
Negative values are considered as lower (minimum)
bounds. Therefore, the constraint is satisfied if the
constraint value is greater than the value you
specify.

A read-only Coordinate System property also displays and is

automatically set to Nodal Coordinate System.

Important:

If you apply a Reaction Force to more than one node,

and the Criteria property is set to Absolute Maximum,
the absolute value for the constraint is met and negative
numbers are no longer allowed. For example, if you enter
a value of 100N, the constraint is satisfied if it meets a
value between -100 and 100.

• Temperature: This option is only available when the upstream

system is Steady-State Thermal. You use this constraint to put an
upper bound on the temperatures using Temperature (Abs Max)
property. This value can be define as a Constant or using Tabular
Data.

• Compliance: This option is only available when there is at least

one upstream Static Structural system. You use this property to

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 Define Response Constraints

Category Properties/Options/Description
make sure that the optimized geometry or structure is stiff enough.
When selected, the Maximum property also displays. Enter a value
in the Maximum property as a Constant or using Tabular Data
entries. When selected, the Compliance Limit property also displays.
The Compliance Limit property enables you to specify an upper
boundary on the Compliance value.

• Criterion: This option is available when there is at least one

upstream Static Structural, Harmonic Response, Modal, or Steady-
State Thermal system. The Criterion constraint enables you to
evaluate relative displacements, such as the difference between
the displacements of two nodes. And it enables you to make sure
that the value of a certain criterion is above or below a given
boundary value or that it is within a given range. When selected,
the following additional properties need to be specified:

– Criteria: This property displays a drop-down list of available

Primary Criterion and Composite Criterion objects (p. 3)
evaluated in the upstream Static Structural analysis.

– Lower Bound: Specify this value or set to Free (default).

– Upper Bound: Specify this value or set to Free (default).

Note:

When you select a Criterion that is scoped to Remote

Point or remote boundary condition (Remote Force or
Remote Displacement), the Base Result property options
Reaction Force and Reaction Moment are not
supported for the Density Based and Lattice Optimization
methods.

Suppressed

Include (No, default) or exclude (Yes) the response constraint.

Environment Selection

The application displays this property when you select the Global Stress,
Local von-Mises Stress, Natural Frequency, Displacement, Reaction
Force, or Temperature options for the Response property. The entry
depends upon your upstream analysis type. Per the upstream system, the
default entry is All Structural, All Modal, or All Steady-State Thermal.
Also included in the drop-down list are the specific upstream systems.

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Category Properties/Options/Description
You can select from one of these systems to specify individual values for
stress, frequency, etc.

Note:

If your Structural Optimization analysis includes multiple

upstream analyses, any constraint that sets the Environ-
ment Selection property to All Static Structural or All
Steady State Thermal, the application only applies the
minimum number of steps as determined from the
upstream analyses. That is, whichever upstream system
has the least number of load steps specified, that is the
value the application uses. Selecting a specific analysis
from the property drop-down list applies the constraint
for all load steps of the selected upstream analysis.

Location When you specify the Response property as Center of Gravity or Moment of
and Ori- Inertia, the Axis property displays in order to specify a desired axis to constrain.
entation Options include X-Axis, Y-Axis, and Z-Axis.

In addition, for the Moment of Inertia option, a Coordinate System property

displays so that you can specify the appropriate Cartesian coordinate system for
the constraint.
[a] Ansys recommends that you use User Defined Criterion (p. 3) to define your criterion of
interest and then specify the criterion in the Objective (p. 55) or Response Constraint
object of your optimization analysis.

Refer to the Response Constraint object reference page for additional information.

2.9. Define Manufacturing Constraints

It is important to understand that a optimization solution could create manufacturable designs. As a
result, any change to the manufacturing process due to an unintended design could undermine the
integrity of the original design. Therefore, you (the designer), should apply and specify manufacturing
constraints based on your manufacturing process. The Manufacturing Constraint condition, when
applied to a optimization system, helps to alleviate design problems by enabling you to specify manu-
facturing limitations.

Go to a section topic:

• Constraint Types (p. 73)

• Subtype Requirements and Restrictions (p. 73)

• Application (p. 75)

• Details Pane Properties (p. 75)

Refer to the Manufacturing Constraint object reference page for additional information.

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 Define Manufacturing Constraints

Constraint Types
The application supports manufacturing constraints, per method, as shown here.

Mixable Density Level Set Based Shape Density Based

Optimization
Member Size Member Size Member Member Size
(Minimum and (Minimum and Size (Minimum and
Maximum Maximum Thickness (Maximum Maximum
Thickness and and Minimum Gap) Thickness) Thickness)
Minimum Gap) Pull Out Direction Extrusion Pull Out
Pull Out (1-sided, 2-sided, Direction
Direction (1-sided Stamping, and (1-sided and
and 2-sided) No-hole) 2-sided)
Extrusion Millability Extrusion
AM Overhang AM Overhang AM Overhang
Constraint Constraint Constraint
Housing Housing
Complexity Index

Requirements and Restrictions

Density Based and Mixable Density Methods

Note the following requirements and restrictions when you are using the Topology Optimization
- Density Based or Topology Optimization - Mixable Based optimization method. The restrictions
only apply when one of the manufacturing constraint types is scoped to an Optimization Region
or if it has an overlapping region.

• If you specify an AM Overhang Constraint manufacturing constraint, in combination with:

– Symmetry, the Build Direction must be in the symmetry plane.

– Cyclic Repetition, the Build Direction must be parallel to the Axis specified for the Cyclic
Repetition.

Note:

This requirement also applies if your Optimization Region includes the

geometry of the low and high faces specified by a Cyclic Region object.

– Pattern Repetition, the Build Direction must be perpendicular to the Axis specified for
the Pattern Repetition.

• If you specify an Extrusion and a Cyclic Repetition Design Constraint, the axis of rotation of
cyclic constraint must be in the same as the extrusion direction.

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Optimization Analysis Workflow

• If you specify an Extrusion and a Symmetry design constraint, the extrusion direction must be
in the symmetry plane.

• If you specify a Pull Out Direction and a Symmetry design constraint, the pull out direction
must be in the symmetry plane.

• If you specify the Pattern Repetition design constraint, in combination with:

– Extrusion, the pattern direction must be perpendicular to the extrusion direction.

– Pull Out Direction, the pull-out direction must be perpendicular to the pattern direction.

• The combination of the following constraint types is not supported:

– Extrusion and Uniform.

– Pull Out Direction and Uniform.

– AM Overhang Constraint and Uniform.

– AM Overhang Constraint and Member Size, Extrusion, or Pull Out Direction.

Level Set Based Method

Note the following requirements and restrictions when you are using the Topology Optimization
- Level Set Based optimization method. The restrictions only apply when one of the manufacturing
constraint types is scoped to an Optimization Region or if it has an overlapping region.

• When you specify a Member Size manufacturing constraint and set the Minimum property
to Manual, the application performs two optimizations. The first one does not consider the
manufacturing constraint in the solution calculation. However, if the constraint's Minimum
value is exceeded at the end of this first run, then a second optimization run is executed
using the constraint specifications. This logic makes sure that the optimization does not be-
come trapped in an irrelevant local minimum.

• If you specify an AM Overhang Constraint manufacturing constraint, in combination with:

– Symmetry, the Build Direction must be in the symmetry plane.

– Cyclic Repetition, the Build Direction must be parallel to the Axis specified for the
Cyclic Repetition.

– Pattern Repetition, the Build Direction must be perpendicular to the Axis specified
for the Pattern Repetition.

• If you specify a Pull Out Direction and a Symmetry design constraint, the pull out direction
must be in the symmetry plane.

• If you specify the Pattern Repetition design constraint, in combination with Pull Out Direc-
tion, the pull-out direction must be perpendicular to the pattern direction.

• You cannot combine a Millability Manufacturing Constraint with any Design Constraint.

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 Define Manufacturing Constraints

Symmetry Using a Cyclic Region

If your Optimization Region includes the geometry of the low and high faces specified by a Cyclic
Region or a Pre-Meshed Cyclic Region object, the following apply, you can specify the following
based on requirements.

Manufacturing Constraints

The following manufacturing constraints have requirements when symmetry is present:

• Millability: Not supported.

• AM Overhang Constraint: The Build Direction must be parallel to the Axis of the cyclic
region.

• Pull-Out Direction: The pull-out direction and axis of symmetry must be the same.

• Extrusion: The axis of symmetry must match the extrusion direction.

Design Constraints

Note the following requirements if your analysis also includes any of these design constraints:

• Cyclic Repetition and Uniform cannot be defined.

• Symmetry: The symmetry plane must be perpendicular to the axis of symmetry.

• Pattern Repetition: The pattern direction must match the axis of symmetry.

Note:

The Housing manufacturing constraint is supported as a Beta Option and has no specific-
ation requirements.

Application
The analysis can include only one Manufacturing Constraint object.

1. To add the object, either look on the Environment Context tab and select Manufacturing Constraint
> [manufacturing constraint type] or right-click the Environment object or within the Geometry
window and select Insert > [manufacturing constraint type].

2. Based on the selected constraint type, specify Details properties as required.

Details Properties
The Details pane for this object includes the following properties.

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Category Properties/Options/Description
Scope Scoping Method: Based upon the type of Manufacturing Constraint you have inserted
into the tree, one or more of the following options is available for this property:

• Geometry Selection: This option indicates that the design region is applied to a
geometry or geometries, which are chosen using the graphical selection tools.
When you specify Geometry Selection for the Scoping Method, the Geometry
property displays.

In this case, use selection filters on the Graphics Toolbar to pick your geometric
entities (body and element selection only), and then click Apply. Once complete,
the property displays the type of geometry (Body, Element, etc.) and the number
of selected geometric entities (for example: 1 Body, 12 Elements).

• Named Selection: This option indicates that the design region is applied to a
Named Selection. When you specify Named Selection for the Scoping Method,
the Named Selection property displays. This property provides a drop-down list
of available user-defined Named Selections (only body-based and element-based
Named Selections are supported).

• Optimization Region: This option indicates that the design region is applied to
the specified Optimization Region. When you select Optimization Region for the
Scoping Method, the Optimization Region Selection property displays and is
automatically set to Optimization Region (the only option).

• All Optimization Regions: When you have multiple Optimization Regions, this
option indicates that the constraint is applied to all defined Optimization Regions.

Defin- Type: This is a read-only property that indicates the object as a Manufacturing Constraint.
i-
tion Subtype: This is a read-only property that displays the type of Manufacturing Constraint
you selected. Options include:

• Member Size: This subtype provides options to specify the minimum thickness,
the maximum thickness, and/or a gap size of the connected parts in the final design.

Note:

For the Mixable Density and Density-Based methods, the solver

provides a density field with values ranging from 0 to 1. Because
intermediate values can occur, the Member Size (min, max, gap)
measurement may be violated in some cases. If you encounter this issue,
try increasing the value to resolve the problem.

• Pull Out Direction: This subtype is used for mold-based manufacturing processes.
It enables you to specify the direction to remove the model from the mold in a
manner that ensures the integrity of the model.

When selected, the Pull Out Option property displays. This property has the
following options:

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 Define Manufacturing Constraints

Category Properties/Options/Description
– None (default): The pull out direction is specified using location and
orientation only.

– Stamping: Selecting this option instructs the application to create a design

that is more compatible with a stamping or forging process. Like the design
of a plate, the final design will not have any perforations along the pull-out
direction.

– No-Hole: Selecting this option makes sure that the design will not have any
perforations. It typically aims to ease the filling stage during the casting
process.

Note:

– For the Density Based method only, if your analysis specifies a

Tetrahedrons Mesh Method (SOLID187) and you are also defining a
Pull Out Direction, Ansys recommends that you also include the
Manufacturing Constraint > Member Size. And, you need to
manually specify the Minimum property of the Member Size to at
least four times the Tetrahedron element size.

– You may experience an Exclusion Region specification that is not

consistent (the shapes differ) with a Pull Out Direction constraint.
For the Topology Optimization – Level Set Based method, the
application automatically reshapes the Exclusion Region in order to
comply with the pullout direction.

• Millability: Create a structure to be manufactured using four-axis milling. Requires

you to specify a Coordinate System and Axis.

• Extrusion: Make sure that the resulting cross section of your final design is kept
constant along the selected plane. For each element of the Optimization Region,
the application requires at least two corner nodes to lie on the Axis specified for
the Extrusion.

• The AM Overhang Constraint is used for additive printing. It creates an Overhang

Angle constraint that uses the input of Overhang Angle and Build Direction to
create self-supporting structures. A structure optimized using AM Overhang Con-
straint can then be 3D printed without (or with reduced) supports. If the application

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Optimization Analysis Workflow

Category Properties/Options/Description
is not able to build supports for all exclusions, it creates as many as possible and
issues a warning.

Note:

See the LPBF Simulation Guide for details about performing additive
manufacturing simulations.

Important:

For the Density-based Method

Note the following restrictions and requirements. The AM Overhang

Constraint:

– Can be specified only once in a Structural Optimization analysis.

– Cannot be used in combination with the Manufacturing

Constraints Member Size (with Maximum Member Size defined),
Extrusion, or Pull Out Direction.

– If used with Symmetry Manufacturing Constraint, the Build

Direction of the AM Overhang constraint must be in the symmetry
plane.

– If used with the Cyclic Repetition Design Constraint, the Build

Direction of the AM Overhang constraint must be parallel to the
Axis selection of the Cyclic Repetition constraint.

• Housing: This manufacturing constraint enables you to create a watertight design

that encloses a given set of faces. Topology optimization often generates designs
that include holes and perforations. Using this manufacturing constraint, you can
create a container to house a given liquid. Ansys recommends that you have at
least three layers of elements above the selected faces. The surrounding edges of
the selected faces will be automatically set as the Exclusion Region.

• Complexity Index: Use the Complexity Index manufacturing constraint to control

the complexity of optimized designs created during the process. Using the associated
Maximum Value property to specify a limit for this qualitative criterion, which is
based on a ratio between the volume and the model’s perimeter, you can minimize
the creation of overly complex structures. An entry value of 1 in the Maximum
Value property forces the application to produce a bulky sphere-like shape. As you
increase the value of this entry, you enable the optimization process to reduce
materials in many free form ways, therefore making the manufacture of the design
more difficult. An entry range of 2-10 is suggested.

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 Define Manufacturing Constraints

Category Properties/Options/Description
Minim- Density Based Method
um
Size When you specify a Member Size constraint for the Topology Optimization -
Con- Density Based method, the following properties display in the Minimum Size
trols Controls category of the Details pane.

• Minimum: For the Density Based optimization method, the options include
Program Controlled (default) and Manual. Using the Program Controlled
setting, the application automatically sets the minimum size equal to the mesh
element size.

Min Size: This property displays when you set Minimum property to Manual.
The application automatically computes a default value for this property using
the mesh size of the generated mesh. This value can simplify the Structural
Optimization solution run. The Program Controlled setting is applicable even
when no Member Size is added to the analysis.

Level Set Based & Mixable Density Methods

When you specify a Member Size constraint for the Topology Optimization -
Level Set Based or the Topology Optimization - Mixable Density methods, the
following properties display in the Minimum Size Controls category of the Details
pane.

• Minimum: Options include Free (default) and Manual.

Min Size: This property displays when you set the Minimum property to
Manual. Use this property to manually enter a desired minimum member size
length.

Maxim- Density Based and Shape Optimization Methods

um
and When you specify a Member Size constraint for the Topology Optimization -
Gap Density Based or Shape Optimization methods, the following properties display
Size in the Maximum and Gap Size Controls category of the Details pane.
Con-
trols • Maximum

For the Topology Optimization - Density Based method, options include

Program Controlled (default) and Manual.

For the Shape Optimization method, options include Free (default) and
Manual.

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Category Properties/Options/Description
Max Size: This property displays when you set the Maximum property to
Manual. Use this property to manually enter a desired maximum member size
length.

Note:

For the Shape Optimization method, the application automatically

increases the (Max Size) value to four times the mesh element size if
the limit is detected to be too small.

Level Set Based & Mixable Density Methods

When you specify a Member Size constraint for the Topology Optimization -
Level Set Based or the Topology Optimization - Mixable Density methods, the
following properties display in the Maximum and Gap Size Controls category
of the Details pane.

• Measurement Type: Options include Isotropic (default) and In-Plane. When

you select the In-Plane option, the following additional properties display:

– Coordinate System: Specify a desired Cartesian coordinate system to

be used by the Plane property.

– Plane: Specify a desired surface plane. Options include XZ Plane, YZ

Plane, and XY Plane.

• Maximum: Options include Free (default) and Manual.

Max Size: This property displays when you set the Maximum property to
Manual. Use this property to manually enter a desired maximum member size
length.

Note:

The application automatically increases the (Max Size) value to four

times the mesh element size if ever the limit is detected to be too
small.

• Gap Size: This property displays when you set the Maximum property to
Manual. The minimum gap constraint can be used only in combination with
the Maximum Member Size constraint. Options include Free (default) and
Manual.

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 Define Manufacturing Constraints

Category Properties/Options/Description
Value: This property displays when you set the Gap Size property to Manual.
Use this property to manually enter a desired member size gap length.

Note:

Ansys recommends that you specify a Gap Size limit that is smaller than
two times the limit for the Maximum Member Size (minGap 2*MaxThick).

Loc- When one of the following subtypes is selected, their associated properties display in the
a- Location and Orientation category of the Details view.
tion
and Pull Out Direction
Ori-
ent- When this constraint type is selected, the following associated properties display:
a-
• Coordinate System: Specify the appropriate Cartesian coordinate system
tion
for material removal.

• Axis: Specify the removal axis. Options include: X-Axis, Y-Axis, Z-Axis.

• Direction: Specify the removal direction based on the above axis. Options
include: Along Axis, Opposite to Axis, or Both Direction.

The Pull Out Direction constraint satisfies the criteria that there is no
concave shape inside of the die so that the part cannot be trapped. This
makes sure that the die can be successfully separated from a part after
forming.
For the options Along Axis and Opposite to Axis only the direction of
the coordinate system is relevant.
For the Topology Optimization - Density Based optimization method,
when the Direction property is set to Both Directions, both the origin
and the axis selection of the coordinate system is important. The Pullout
Constraint is applied from the normal plane (normal to the coordinate
system axis selection) at the origin and along and opposite to the direction
specified by the coordinate system axis.

Millability

When this constraint type is selected, the following associated properties display:

• Coordinate System: Specify an appropriate Cartesian coordinate system.

• Axis: Specify the axis around which the rotation occurs. Options include:
X-Axis (default), Y-Axis, Z-Axis. See the Millability (p. 237) section for more
information.

Extrusion

When this constraint type is selected, the following associated properties display:

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Optimization Analysis Workflow

Category Properties/Options/Description
• Coordinate System: Specify the appropriate Cartesian coordinate system
for the extrusion.

• Axis: Specify the extrusion axis. Options include: X-Axis, Y-Axis, Z-Axis.

AM Overhang Constraint

When this constraint type is selected, the following associated properties display:

• Coordinate System: You use this property to specify the appropriate

Cartesian coordinate system for the overhang angle. By default, this
property is set to the Global Coordinate System. You can specify a
user-defined Coordinate System as desired.

• Build Direction: You use this property to specify the direction that you
would like the overhang constraint to be applied. Options include +X Axis,
+Y Axis, +Z Axis (default), -X Axis, -Y Axis, and -Z Axis.

• Overhang Angle: You use this property to specify the degree to which
the constraint should be applied. The default setting is 45°.

Note:

For the density based optimization method, the angle should

be kept between 27° and 60°.

Housing

When this manufacturing constraint type is selected, the following associated

properties display:

• Scoping Method: Specify how you want to select the region, either using
Geometry Selection or using a Named Selection.

• Geometry: Select your geometry or mesh entities that you want to use to
create a watertight cavity. Only node, edge, or face selections are supported.

• Named Selection: Select a geometry-based or mesh-based Named Selection

to be used to create a watertight cavity. Only Named Selections defined
by nodes, edges, or faces are supported.

Part- Parting Surface Control: Specify whether the parting surface is unconstrained or has an
ing imposed constraint. Options include:
Sur-
face • Free (default): Leave the parting surface unconstrained.
Con-
• Force Plane: Use this option to impose a parting surface. When selected, the
following additional properties display:

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 Define Design Constraints

Category Properties/Options/Description
trol – Parting Surface Coordinate System: Specify an appropriate Cartesian
[a] coordinate system to align the parting surface.
Group
– Parting Surface Plane: Specify a plane that serves as parting surface. Options
include: XY Plane, XZ Plane, YZ Plane.

[a] This category is only available for the Topology Optimization - Level-Set method when
the Direction property is set to Both Directions.

2.10. Define Design Constraints

Like the options of the Manufacturing Constraint capability, the options of the Design Constraint
capability, as listed below, enable you to impose specific design requirements.

• Cyclic Repetition: This option enables you to control how the sectors are repeated, at the required
times, along the specified axis and yields a design that is symmetric with respect to an axis of rotation.

• Symmetry: This option enables you to enforce a design that is symmetric with respect to a user-
defined plane.

• Uniform: This option enforces a design that has a constant Topology Density on all planes parallel
to a user-defined plane.

• Pattern Repetition: This option enforces a design that has a repetitive pattern. The pattern is repeated
along the specified axial plane with a user-defined offset value.

Go to a section topic:

Supported Optimization Methods (p. 83)

Subtype Requirements and Restrictions for Density Based Method (p. 84)
Application (p. 85)
Details Pane Properties (p. 85)

Supported Optimization Methods

The Design Constraint options are supported for the following methods only:

Density Lattice Level Set Mixable Shape Topography Materials

Based Optimization Based Density Optimization Optimization Optimization
Cyclic Pattern Cyclic Cyclic Cyclic Not Cyclic
Repetition Repetition Repetition Repetition Repetition Applicable Repetition
Symmetry Cyclic Symmetry Symmetry Symmetry Symmetry
Uniform Repetition Pattern Pattern
Pattern Symmetry Repetition Repetition
Repetition

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Optimization Analysis Workflow

Requirements and Restrictions

Note the following requirements and restrictions for design constraint types. The restrictions only apply
when one of the types is scoped to an Optimization Region or if it has an overlapping region.

• Only one Uniform constraint can be specified per analysis.

• Only one Cyclic Repetition constraint can be specified per analysis.

• If you specify two Symmetry constraints, the symmetry planes must be perpendicular to one
another.

• If you specify a Symmetry and a Cyclic Repetition, the given symmetry plane must be perpen-
dicular to the axis of rotation.

• If you specify a Symmetry and a Uniform, the symmetry plane must be parallel to the plane of
the uniform constraint.

• If you specify two Pattern Repetition constraints, the axis planes must be perpendicular to one
another.

• The combination of the following subtypes is not supported:

– Cyclic Repetition and Uniform

– Extrusion and Uniform

– Pull Out Direction and Uniform

• Note the following restrictions when you specify a Manufacturing Constraint and a Design
Constraint with the Subtype combinations:

– For Symmetry and Extrusion, the extrusion direction must be in the symmetry plane.

– For Symmetry and Pull Out Direction, the pull out direction must be in the symmetry
plane.

– For Cyclic Repetition and Extrusion, the axis of rotation of cyclic constraint must be in
the same as the extrusion direction.

– For Cyclic Repetition and Pull Out Direction, the pull out direction and the cyclic axis
of rotation must be the same.

• If you specify Pattern Repetition, in combination with:

– Symmetry, the pattern direction must be in the symmetry plane.

– Cyclic Repetition, the pattern direction must be the same as the rotation axis.

– Extrusion, the pattern direction must be perpendicular to the extrusion direction.

– Pull Out Direction, the pull-out direction must be perpendicular to the pattern direction.

– Uniform, the plane of the uniform constraint must be perpendicular to the pattern direction.

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 Define Design Constraints

Application
The analysis can include only one Design Constraint object.

1. To add the object, either look on the Environment Context tab and select Design Constraint >
[Subtype] or right-click the Environment object or within the Geometry window and select Insert
> [Subtype].

2. Based on the selected Subtype, specify properties as required.

Details Properties
The Details pane for this object includes the following properties.

Category Properties/Options/Description
Scope Scoping Method: Based upon the type of Design Constraint you have inserted
into the tree, one or more of the following options is available for this property:

• Geometry Selection: This option indicates that the design region is applied
to a geometry or geometries, which are chosen using the graphical selection
tools. When you specify Geometry Selection for the Scoping Method, the
Geometry property displays.

In this case, use selection filters on the Graphics Toolbar to pick your
geometric entities (body and element selection only), and then click Apply.
Once complete, the property displays the type of geometry (Body, Element,
etc.) and the number of selected geometric entities (for example: 1 Body,
12 Elements).

• Named Selection: This option indicates that the design region is applied
to a Named Selection. When you specify Named Selection for the Scoping
Method, the Named Selection property displays. This property provides a
drop-down list of available user-defined Named Selections (only body-based
and element-based Named Selections are supported).

• Optimization Region: This option indicates that the design region applied
to the specified Optimization Region. When you select Optimization
Region for the Scoping Method, the Optimization Region Selection
property displays.

• All Optimization Regions: When you have multiple Optimization Regions,

this option indicates that the constraint is applied to all defined Optimization
Regions.

Definition Type: This is a read-only property that indicates the object as a Design Constraint.

Subtype: This property is a read-only field and it displays the type of Design
Constraint you selected from the Design Constraint drop-down menu.

• Cyclic Repetition

• Symmetry

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Optimization Analysis Workflow

Category Properties/Options/Description
• Uniform

• Pattern Repetition

Location When a subtype is selected, their associated properties display in the Location
and Ori- and Orientation category of the Details:
entation
Cyclic Repetition

When this subtype is selected, the following associated properties display:

• Number of Sectors: This property specifies the appropriate number

of sectors.

• Coordinate System: Specify an appropriate Cartesian or Cylindrical

coordinate system for the cyclic model.

• Axis: Specify the appropriate axis. Options include: X-Axis, Y-Axis,

Z-Axis. Only the Z-Axis option is supported for a Cylindrical
coordinate system.

Symmetry

When this subtype is selected, the following associated properties display:

• Coordinate System: Specify the appropriate Cartesian coordinate

system for the symmetry model.

• Axis: Specify the plane for the symmetry model. Options include:
YZ Plane, XZ Plane, and XY Plane.

Uniform

When this subtype is selected, the following associated properties display:

• Coordinate System: Specify the appropriate Cartesian coordinate system

for the uniform constraint.

• Axis: Specify the appropriate plane. Options include: YZ Plane, XZ Plane,

and XY Plane.

Pattern Repetition

When this subtype is selected, the following associated properties display:

• Coordinate System: Specify the appropriate Cartesian coordinate system

for the repetitive pattern.

• Axis: Specify the appropriate axis. Options include: X-Axis, Y-Axis, and
Z-Axis.

• Offset: Specify the appropriate offset after which the pattern is repeated.

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 Specify Results and Solve

2.11. Specify Results and Solve

The optimization analysis supports the following results. Refer to the individual sections for more in-
formation.

• Topology Density (p. 88) (inserted automatically)

• Topology Elemental Density (p. 92)

• Lattice Density (p. 149)

• Topology Multi-Density (p. 95)

• Structural Results (p. 97): Supported structural results include Deformation, Stress, and Strain results.
To evaluate these results, you must create solution data using the Export Design Properties property.
See the Specify Analysis Settings (p. 24) section for more information about the settings of the Export
Design Properties property.

Note:

Upstream Harmonic Response analyses do not support the export of structural results.

• Thermal Results (p. 100): Supported thermal results include Temperature and Heat Flux (Directional
and Total). To evaluate these results, you must create solution data using the Export Design Properties
property. See the Specify Analysis Settings (p. 24) section for more information about the settings
of the Export Design Properties property.

• User Defined Results: User Defined Results are available using the context (right-click) option on the
Worksheet for the Available Solution Quantities.

• Topology Density Tracker Result Plot Tracker (inserted automatically)

Note:

The Mechanical APDL solver supports the use of the Commands (APDL) object for optimization
analyses. This support includes all iterations of the optimization analysis and for all load
steps.

Important:

If you are using the Remote Solve Manager (RSM) for your solution, the density trackers do
not update during the solution process. In order to see an optimization update for your
model, you need to select the tracker object, right-click, and select the option Evaluate All
Results. This action tells the remote machine to read the appropriate local file and display
the current results.

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Optimization Analysis Workflow

2.11.1. Topology Density

The Topology Density result produces nodal averaged results. Go directly to a section topic using
the following links:

• Application (p. 88)

• Display Limitations (p. 88)

• Result Smoothing (p. 88)

• Specify Properties (p. 89)

• Shared Topology Display Issue (p. 91)

Application
One Topology Density object is added automatically to the optimization analysis system. You can
add additional objects by selecting Topology Density from the Results group on the Solution
Context tab or by right-clicking the Solution folder (or in the Geometry window) and selecting In-
sert>Topology Density.

Note:

You can further analyze your optimized model, through continued simulation or by per-
forming a design validation by exporting your results and making them available to a new
downstream system.

The Solution object property Export Topology (STL file) enables you to automatically
export your results in Standard Tessellation Language (STL) and in Part Manager Database
(PMDB) file format, archive the files in zip file format, and then place the zipped file in the
Solver Files Directory. This option is set to Yes by default.

In order to make the optimized results available to a downstream system, you need to
create the new system on the Workbench Project Schematic and link the Results cell of
your Structural Optimization analysis to the Geometry cell of a new downstream system,
either a Geometry component system or the Geometry cell of another analysis system.
Refer to the Design Validation (p. 111) section for additional details about this process.

Display Limitation
This result type does not support the display options available from the Geometry drop-down menu
on the Result Context tab and that include the following views: Exterior, IsoSurfaces, Capped
IsoSurfaces, and Section Planes.

Result Smoothing
The Topology Density result offers the Results group option Smoothing from the Solution Context
Tab. You can also insert a Smoothing object using the context (right-click) menu options Insert >
Smoothing. This result generates an STL (Stereolithography) file based on the Topology Density
result that you can need modify to move nodes of the geometry to refine your part and as desired,

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 Specify Results and Solve

save for use in downstream validation systems. Multiple Smoothing objects can be added for each
Topology Density result.

Note:

Smoothing is not supported on the Linux platform.

Specify Properties
Using the properties of the Details pane, define results.

Category Properties/Options/Description
Scope Scoping Method. The options for this property include:

• Optimization Region (default): This option indicates that the design

region is applied to the specified Optimization Region. When you select
Optimization Region for the Scoping Method, the Optimization Region
property displays.

• Geometry Selection: This option indicates that the design region is applied
to a geometry or geometries, which are chosen using the graphical
selection tools. When you specify Geometry Selection for the Scoping
Method, the Geometry property displays.

In this case, use selection filters on the Graphics Toolbar to pick your
geometric entities (body and element selection only), and then click Apply.
Once complete, the property displays the type of geometry (Body, Element,
etc.) and the number of selected geometric entities (for example: 1 Body,
12 Elements).

• Named Selection: This option indicates that the design region is applied
to a Named Selection. When you specify Named Selection for the Scoping
Method, the Named Selection property displays. This property provides
a drop-down list of available user-defined Named Selections (only
body-based and element-based Named Selections are supported).

Defini- Type: Read-only field that describes the object - Topology Density.
tion
Starting at Sector: Define which sectors are included in the expanded display
of results. Visible only when your analysis includes Symmetry specified using
either the Cyclic Region or Pre-Meshed Cyclic Region objects. Select the specific
sectors to include within the expansion.

Note:

Use the Number of Sectors property of the of the Cyclic Solution

Display category of the Details pane of the Solution object to
specify the total number of sectors.

By: Read-only field that displays "Iteration".

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Optimization Analysis Workflow

Category Properties/Options/Description
Iteration: The default setting is Last. You can specify an iteration number to
obtain results for the specified iteration (displayed in the Result category).

Note:

The animation of Topology Density results occurs over all

iterations for which the intermediate results are computed as well
as saved during solution. The intermediate results are computed
based on the setting of the Store Results At property of the
Output Controls (Analysis Settings object) and the intermediate
results are saved to disk based on the setting of the Max Num
of Intermediate Files property.

Retained Threshold: This property is controlled by a slider that represents the

range from minimum to maximum for the result. The default value is 0.5. The
supported range is 0.01 to 0.99 (greater than zero and less than 1).

Once you evaluate the result, use the slider to view the optimized topology in
the graphics view. The application computes and displays the values for the
Original Volume, Final Volume, Percent Volume of Original, Original Mass, Final
Mass, and Percent Mass of Original properties.

Exclusions Participation: Yes (default) or No. When set to Yes, the application
uses the excluded elements to compute the Original Volume, Final Volume,
Percent Volume of Original, Original Mass, Final Mass, and Percent Mass of Original
properties. When set to No, excluded elements are not considered.

Suppressed: Include (No, default) or exclude (Yes) the result.

Results Minimum: Read-only field that displays minimum density value of the result.

Maximum: Read-only field that displays maximum density value of the result.

Original Volume: Read-only field that displays, per scoping, the computed original
volume.

Final Volume: Read-only field that displays, per scoping and the Retained
Threshold setting, the optimized volume.

Percent Volume of Original: Read-only field that displays the value of the Final
Volume divided by the Original Volume.

Original Mass: Read-only field that displays, per scoping, the computed original
mass.

Final Mass: Read-only field that displays, per scoping and the Retained Threshold
setting, the optimized mass.

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 Specify Results and Solve

Category Properties/Options/Description
Percent Mass of Original: Read-only field that displays the value of the Final
Mass divided by the Original Mass.

Note:

If elements are excluded from the optimization, then volume/mass

contribution from those elements will not be included in the Original
Volume/Original Mass computation.

Visibility Show Optimized Region: This property is used to control graphical view changes
only. The options for this property include:

• All Regions: This option displays all of the regions selected by the Scoping
Method. Three color bands are shown: Remove (Red), Marginal (Yellow),
and Keep (Gray). Remove indicates a Retained Threshold value of 0 to
0.4, Marginal indicates a value of 0.4 to 0.6, and Keep indicates a value
greater than 0.6.

• Retained Region (default): When Retained Region is selected, then the

Retained Threshold value is used from the details view to show the
region which must be kept.

• Removed Region: This option displays what will be removed.

Informa- Iteration Number: Read-only field that displays the converged iteration step
tion number.

Shared Topology Display Issue

If you are using the Density Based, Level Set, or Mixable Density optimization methods, there is a
known graphical display issue when you optimize a body that is connected to another unoptimized
body using Shared Topology. The unoptimized body may display modifications that do not actually
exist, as illustrated below.

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Optimization Analysis Workflow

Because the optimized and non-optimized bodies share nodes at the contact region, the non-optimized
body appears modified at the contact surfaces. However, no actual change has taken place to the
non-optimized body.

2.11.2. Topology Elemental Density

The Topology Elemental Density result produces element-based result values. Go directly to a section
topic using the following links:

• Application (p. 92)

• Display Limitations (p. 93)

• Specify Properties (p. 93)

Application
You can add the object (or objects) by selecting Topology Elemental Density from the Results group
on the Solution Context tab or by right-clicking the Solution folder (or in the Geometry window)
and selecting Insert > Topology Elemental Density.

Note:

You can further analyze your optimized model, through continued simulation or by per-
forming a design validation by exporting your results and making them available to a new
downstream system.

The Solution object property Export Topology (STL file) enables you to automatically
export your results in Standard Tessellation Language (STL) and in Part Manager Database

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 Specify Results and Solve

(PMDB) file format, archive the files in zip file format, and then place the zipped file in the
Solver Files Directory. This option is set to Yes by default.

In order to make the optimized results available to a downstream system, you need to
create the new system on the Workbench Project Schematic and link the Results cell of
your Structural Optimization analysis to the Geometry cell of a new downstream system,
either a Geometry component system or the Geometry cell of another analysis system.
Refer to the Design Validation (p. 111) section for additional details about this process.

Display Limitation
This result type does not support the following display options available from the Geometry drop-
down menu on the Result Context Tab:

• Exterior

• IsoSurfaces

• Capped IsoSurfaces

• Section Planes

Specify Properties
Using the properties of the Details pane, define results.

Category Properties/Options/Description
Scope Scoping Method. The options for this property include:

• Optimization Region (default): This option indicates that the design

region is applied to the specified Optimization Region. When you select
Optimization Region for the Scoping Method, the Optimization Region
property displays.

• Geometry Selection: This option indicates that the design region is applied
to a geometry or geometries, which are chosen using the graphical
selection tools. When you specify Geometry Selection for the Scoping
Method, the Geometry property displays.

In this case, use selection filters on the Graphics Toolbar to pick your
geometric entities (body and element selection only), and then click Apply.
Once complete, the property displays the type of geometry (Body, Element,
etc.) and the number of selected geometric entities (for example: 1 Body,
12 Elements).

• Named Selection: This option indicates that the design region is applied
to a Named Selection. When you specify Named Selection for the Scoping
Method, the Named Selection property displays. This property provides
a drop-down list of available user-defined Named Selections (only
body-based and element-based Named Selections are supported).

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Optimization Analysis Workflow

Category Properties/Options/Description
Defini- Type: Read-only field that describes the object - Topology Elemental Density.
tion
Starting at Sector: Define an individual sector to be displayed. This result does
not support the visual expansion of all sectors, only the specified sector. Visible
only when your analysis includes Symmetry specified using either the Cyclic
Region or Pre-Meshed Cyclic Region objects.

Note:

This result is not affected by the settings of the Cyclic Solution

Display category of the Details pane of the Solution object. The
application performs calculations only on the base sector of the
model.

By: Read-only field that displays "Iteration."

Iteration: The default setting is Last. You can specify an iteration number to
obtain results for the specified iteration (displayed in the Result category).

Note:

The animation of Topology Density results occurs over all

iterations for which the intermediate results are computed as well
as saved during solution. The intermediate results are computed
based on the setting of the Store Results At property of the
Output Controls (Analysis Settings object) and the intermediate
results are saved to disk based on the setting of the Max Num
of Intermediate Files property.

Retained Threshold: This property is controlled by a slider that represents the

range from minimum to maximum for the result. The default value is 0.5. The
supported range is 0.01 to 0.99 (greater than zero and less than 1). Once you
evaluate the result, use the slider to view the optimized topology in the graphics
view. The application computes and displays the values for the Original Volume,
Final Volume, Percent Volume of Original, Original Mass, Final Mass, and Percent
Mass of Original properties.

Exclusions Participation: Yes (default) or No. When set to Yes, the application
uses the excluded elements to compute the Original Volume, Final Volume,
Percent Volume of Original, Original Mass, Final Mass, and Percent Mass of Original
properties. When set to No, excluded elements are not considered.

Suppressed: Yes or No (default).

Results Minimum: Read-only field that displays minimum value of the result.

Maximum: Read-only field that displays maximum value of the result.

Original Volume: Read-only field that displays, per scoping, the computed original
volume.

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 Specify Results and Solve

Category Properties/Options/Description
Final Volume: Read-only field that displays, per scoping and the Retained
Threshold setting, the optimized volume.

Percent Volume of Original: Read-only field that displays the value of the Final
Volume divided by the Original Volume.

Original Mass: Read-only field that displays, per scoping, the computed original
mass.

Final Mass: Read-only field that displays, per scoping and the Retained Threshold
setting, the optimized mass.

Percent Mass of Original: Read-only field that displays the value of the Final
Mass divided by the Original Mass.
Visibility Show Optimized Region: This property is only used to control graphical view
changes. The options for this property include:

• All Regions: This option displays all of the regions selected by the Scoping
Method. Three color bands display: Remove (Red), Marginal (Yellow), and
Keep (Gray). Remove indicates a Retained Threshold value of 0 to 0.4,
Marginal value indicates a value of 0.4 to 0.6, and Keep value indicates a
value greater than 0.6.

• Retained Region (default): When Retained region is selected, then the

Retained Threshold value is used from the details view to show the region
which must be kept.

• Removed Region: This option displays what will be removed.

Informa- Iteration Number: Read-only field that displays the converged iteration step
tion number.

2.11.3. Topology Multi-Density

The Topology Multi-Density result produces nodal averaged results per material.

Go to a section topic:

• Application (p. 95)

• Display Limitations (p. 96)

• Result Smoothing (p. 96)

• Specify Properties (p. 96)

Application
One Topology Multi-Density object is added automatically to the optimization analysis system when
performing a Materials Optimization analysis. You can add additional objects by selecting Topology

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Optimization Analysis Workflow

Multi-Density from the Results group on the Solution Context tab or by right-clicking the Solution
folder (or in the Geometry window) and selecting Insert > Topology Multi-Density.

Display Limitation
This result type does not support the following display options available from the Geometry drop-
down menu on the Result Context Tab:

• Exterior

• IsoSurfaces

• Capped IsoSurfaces

• Section Planes

Result Smoothing
The Topology Multi-Density result offers the Results group option Smoothing from the Solution
Context Tab. You can also insert a Smoothing object using the context (right-click) menu options
Insert > Smoothing. This result generates an STL (Stereolithography) file based on the Topology
Multi-Density result that you can modify to move nodes of the geometry to refine your part and as
desired, save for use in downstream validation systems. Multiple Smoothing objects can be added
for each result. Note that it generates one smoothed object for all materials.

Note:

Smoothing is not supported on the Linux platform.

Specify Properties
Use the properties of the Details pane to define your result.

Category Properties/Options/Description
Scope Scoping Method. Property options include:

• Optimization Region (default): This option indicates that the design region is applied
to the specified Optimization Region. When you select Optimization Region for the
Scoping Method, the Optimization Region property displays.

• Geometry Selection: This option indicates that the design region is applied to a
geometry or geometries, which are chosen using the graphical selection tools. When
you specify Geometry Selection for the Scoping Method, the Geometry property
displays.

In this case, use selection filters on the Graphics Toolbar to pick your geometric entities
(body and element selection only), and then click Apply. Once complete, the property
displays the type of geometry (Body, Element, etc.) and the number of selected
geometric entities (for example: 1 Body, 12 Elements).

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 Specify Results and Solve

Category Properties/Options/Description
• Named Selection: This option indicates that the design region is applied to a Named
Selection. When you specify Named Selection for the Scoping Method, the Named
Selection property displays. This property provides a drop-down list of available
user-defined Named Selections (only body-based and element-based Named Selections
are supported).

Defin- Type: Read-only field that describes the object - Topology Multi-Density.
i-
tion By: Read-only field that displays the entry Iteration.

Iteration: The default setting is Last. You can specify an iteration number to obtain
results for the specified iteration (displayed in the Result category).

Note:

The animation of Topology Multi-Density results occurs over all iterations

for which the intermediate results are computed as well as saved during
solution. The intermediate results are computed based on the setting of the
Store Results At property of the Output Controls (Analysis Settings object)
and the intermediate results are saved to disk based on the setting of the
Max Num of Intermediate Files property.

Suppressed: Include (No, default) or exclude (Yes) the result.

Res- Minimum: Read-only field that displays minimum density value of the result.
ults
Maximum: Read-only field that displays maximum density value of the result.
In- Iteration Number: Read-only field that displays the converged iteration step number.
form-
a-
tion

2.11.4. Structural Results

The Structural Optimization analysis supports certain structural results, including Deformation, Stress,
and Strain, etc.

Important:

Stress- and strain-based results are not supported for the Topology Optimization -
Density Based method.

Note:

• Optimized structural results are displayed on a triangle-based surface-mesh.

• Upstream Harmonic Response analyses do not support the export of structural results.

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Optimization Analysis Workflow

Application
1. Set the Export Design Properties property (shown below) to a desired option. This property is
included in the Output Controls category of the Analysis Settings object. See the Specify Ana-
lysis Settings (p. 24) section for a description of the options based on the selected optimization
method. This property is available for all optimization methods.

2. Insert results from the appropriate menu (Deformation, Stress, or Strain) on the Solution tab or
using the context (right-click) menu options on the Solution object.

Deformation Result Menu

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 Specify Results and Solve

Stress and Strain Result Menus

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Optimization Analysis Workflow

Once you have specified a result, you specify the properties as you normally would (see results object
reference), except there are the following properties with specific requirements for Structural Optim-
ization:

• Environment Selection: You use this property to select the upstream system from which the
result obtains data.

• Starting at Sector: Define which sectors are included in the expanded display of results. Visible
only when your analysis includes Symmetry specified using either the Cyclic Region or Pre-
Meshed Cyclic Region objects. Select the specific sectors to include within the expansion.

Note:

These results are not affected by the settings of the Cyclic Solution Display
category of the Details pane of the Solution object. The application performs
calculations only on the base sector of the model.

• Set Number: This option displays the contour result for a given Result Set contained in the
result file. By default, this value is the last set. If only one set is available, then that is the spe-
cified Result Set. For a solution that includes load steps and modes, you specify the desired
set using the Set Number property (see Result Set Listing).

• Iteration: This property displays the result set from which the result was obtained. Contours
for the result are based on the data of the iterations. By default, this value is the last iteration.
If only one iteration is available, then that is the specified Iteration. To obtain other iterations,
set the Export Design Properties property to All Accepted Iterations.

2.11.5. Thermal Results

The Structural Optimization analysis supports certain thermal results, including Temperature, Direc-
tional Heat Flux, and Total Heat Flux.

Application
1. Set the Export Design Properties property (shown below) to a desired option. This property is
included in the Output Controls category of the Analysis Settings object. See the Specify Ana-
lysis Settings (p. 24) section for a description of the options based on the selected optimization
methods. This property is available for all optimization methods.

2. To evaluate thermal results available, you need to create solution data using the options the
Export Design Properties property (shown below) of the Output Controls category of the
Analysis Settings object. See the Specify Analysis Settings (p. 24) section for a description of
the options based on the selected optimization methods. This property is available for all optim-
ization methods.

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 Specify Results and Solve

Once specified, you can create temperature and heat flux results. Insert results from the Thermal
menu on the Solution tab or using the using the context (right-click) menu options of the Solution
object.

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Optimization Analysis Workflow

Once you have specified a result, you specify the properties as you normally would (see results object
reference), except there are the following properties with specific requirements for Structural Optim-
ization:

• Environment Selection: You use this property to select the upstream system from which the
result obtains data.

• Starting at Sector: Define which sectors are included in the expanded display of results. Visible
only when your analysis includes Symmetry specified using either the Cyclic Region or Pre-
Meshed Cyclic Region objects. Select the specific sectors to include within the expansion.

Note:

These results are not affected by the settings of the Cyclic Solution Display
category of the Details pane of the Solution object. The application performs
calculations only on the base sector of the model.

• Set Number: This option displays the contour result for a given Result Set contained in the
result file. By default, this value is the last set. If only one set is available, then that is the spe-

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 Post Processing

cified Result Set. For a solution that includes load steps and modes, you specify the desired
set using the Set Number property (see Result Set Listing).

• Iteration: This property displays the result set from which the result was obtained. Contours
for the result are based on the data of the iterations. By default, this value is the last iteration.
If only one iteration is available, then that is the specified Iteration. To obtain other iterations,
set the Export Design Properties property to All Accepted Iterations.

2.12. Post Processing

Once your analysis is prepared and you are ready to begin the solution process, the application enables
you to view the progress of different solution elements, including response convergence charts, using
the output features of the Solution Information object.

Go directly to a section topic using the following links:

• Interrupting the Solution (p. 104)

• Stopping the Solution (p. 104)

• Reviewing Results (p. 104)

• Result Tracker Display Feature (p. 105)

Important:

• If your upstream system is a single Static Structural analysis, it is recommended that you
use step-based loading to improve scalability. In order to do so, you need to define your
loading conditions using the Tabular Data window and you need to set the Independent
Variable property to the Step option. This does not include the use of the Thermal Con-
dition load.

• If you are using the Remote Solve Manager (RSM) for your solution, the density trackers
do not automatically update during the solution process. In order to see an optimization
update for your model, you need to select the tracker object, right-click, and select the
option Evaluate All Results. This action tells the remote machine to read the appropriate
local file and display the current results.

• For a Modal analysis: your Structural Optimization analysis will terminate prior to completion
if every iteration of the optimization run is not able to extract the maximum number of
modes specified from the modal solver.

• The solver unit system specified in the analysis settings of the Static Structural or Modal
analysis needs to match the unit system specified in the Structural Optimization analysis.
If not, the optimization run presents a unit system mismatch error.

For a general overview of the solution process, see the Solve section of the Help.

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Optimization Analysis Workflow

Interrupting the Solution

After you have started the solution process, you can interrupt the solution using the Interrupt Solution
button on the solve dialog box. The state of the optimization system will change and you will receive
a green check mark on the dialog box, even if the solution is not converged completely. The following
message will display:

"The solution ran for iterations and aborted as you requested. Examine the convergence plots
to determine if this is an acceptable solution."

Stopping the Solution

You can stop the solution process using the Stop Solution button on the solve dialog box. The applic-
ation immediately halts the solution, does not write results data and issues the following message:

"The solution process was aborted as you requested."

Reviewing Results
For the Density Based optimization type, you can increase and decrease the boundary of the shape
displayed by the tracker using the Retained Threshold property. This property provides a scalable
slider feature to increase and decrease the displayed threshold of the removed/retained elements on
the model.

For the Level Set Based optimization type, the use of the Retained Threshold property is not relevant.
The shape is clearly and unambiguously defined, removing the need for any interpretation.

See the Topology Density (p. 88) and the Topology Elemental Density (p. 92) sections for descriptions
of the purpose and use of the results specific to a the analysis.

Note:

You can further analyze your optimized model, through continued simulation or by performing
a design validation by exporting your results and making them available to a new downstream
system.

The Solution object property Export Topology (STL file) enables you to automatically export
your results in Standard Tessellation Language (STL) and in Part Manager Database (PMDB)
file format, archive the files in zip file format, and then place the zipped file in the Solver
Files Directory. This option is set to Yes by default.

In order to make the optimized results available to a downstream system, you need to create
the new system on the Workbench Project Schematic and link the Results cell of your
Structural Optimization analysis to the Geometry cell of a new downstream system, either
a Geometry component system or the Geometry cell of another analysis system. Refer to the
Design Validation (p. 111) section for additional details about this process.

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 Post Processing

Result Tracker Display Feature

In addition, by default, application automatically inserts a result tracker object under the Solution In-
formation object. The name of this object depends upon the method you have selected. For example,
a Topology Density Tracker object is illustrated below.

Select this object to view the optimization of the model during the solution. The content of the display
is determined by the setting of the Show Optimized Region property. For the density-based optimiz-
ation method, the options include: Retained Region (default), Removed Region, and All Regions.
Note that the All Regions option displays only color changes on the model.

Note the following behaviors of the tracker and its properties:

• The display is only available when the tracker object is selected during the solution.

• If a tracker object is not selected during the solution process, by default, the application displays
the result of the final iteration.

• The Iteration Number property of the tracker object indicates the iteration number of the result
currently displayed in the Geometry window based on the setting of the Update Interval
property of the Solution Information object.

Here is an animation of a Topology Density Tracker progressing though the solution.

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Optimization Analysis Workflow

2.13. Recreating CAD Geometry

You can insert a downstream Geometry system in order to transfer your faceted geometry to Discovery
Modeling to recreate your CAD geometry using the reverse engineering feature.

Important:

The capability to recreate a downstream geometry is not supported for 2D plane, shell, and
multi-body geometries.

Application
This workflow assumes that you have a working knowledge of Workbench and its component systems.
To create a new geometry from your optimized analysis:

1. Place a new Geometry system on the Project Schematic as illustrated and link the Results cell of
the Structural Optimization system to the Geometry cell of your new system.

2. Select the Results cell of the Structural Optimization system. In the properties pane, set the Geo-
metry Format property to Grouped Obj (default).

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 Recreating CAD Geometry

3. Right-click the Results cell of the Structural Optimization system and select Update. Once complete,
refresh the Geometry cell of the new system.

4. Open the geometry in Discovery Modeling and use the reverse engineering feature to specify your
geometry.

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Optimization Analysis Workflow

Note:

For a Topology Result (p. 88), you can create and export an STL file by 1) using the Export
Topology (STL file) property on the solution object, or 2) using a Smoothing object. An STL
file generated from a Smoothing object is specifically designed for the reverse engineering
capability.

Example
The following sequence shows an example of the original geometry, the optimized geometry, and the
recreated geometry.

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 Recreating CAD Geometry

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Optimization Analysis Workflow

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 Performing Design Validation

2.14. Performing Design Validation

Once you have completed your optimization analysis, you can validate your optimized design in a
downstream analysis system. In order to perform a validation, your optimization analysis must be in a
solved state. Two validation options are available:

• Transfer to Design Validation System (Geometry) (p. 112): This option enables you to first revise
your geometry in a CAD application. No environmental conditions are transferred to the down-
stream system.

• Transfer to Design Validation System (Model) (p. 116): This option enables you to transfer
scoping downstream.

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Optimization Analysis Workflow

2.14.1. Geometry Validation

Design validation using the Transfer to Design Validation System (Geometry) option transfers data
to the downstream system's Geometry cell. The benefit of this option is that you can revise the
geometry in a CAD application. Follow the steps below to validate your simulation.

Note:

As desired, you can use Non-Ansys tools to validate your design. You will need to retrieve
the STL file of the optimized design in order to import it into the geometry modeling
software of your choice.

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 Performing Design Validation

Create Validation System

To validate your optimized topology, actions are required in Mechanical as well as Workbench.

File Preparation in Mechanical

The optimized geometry file - in Standard Tessellation Language (STL) - is created from the selected
Topology Density result picked using the --Topology Result property of the Solution object of the
optimization system in Mechanical. The --Topology Result property only appears when the property
Export Optimal Shape is set to Only Geometry.

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Optimization Analysis Workflow

By having both geometries available in the Geometry cell (in Workbench), you can perform actions
such as overlaying or preserving sections of the geometry or sweep surfaces in order to create addi-
tional material around selected regions such as bolt holes.

Note:

If you decide to use Discovery Modeling to adjust the optimized geometry, check the Ad-
ditive Manufacturing section (as well as the Designing, Repairing problems, and Pre-
paring designs for analysis sections) in the Discovery Modeling Help for the tools you
can use to simplify and prepare the optimized geometry in the new system.

Create Design Validation System in Workbench

Once you have specified the desired result to export and solved the analysis, return to Workbench.
As shown below, the highlighted context menu option Transfer to Design Validation System
(Geometry) becomes available to transfer the Results cell of your completed analysis to either the
Geometry cell or the Model cell of a newly created system. To begin this process, right-click the
Structural Optimization's Results cell and select the Transfer to Design Validation System (Geometry)
option from the menu.

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 Performing Design Validation

Note:

The operation is the same if you have multiple upstream systems.

Once you select the option, Workbench creates a new Mechanical system of the same type that is
upstream of the optimization system and send the original geometry and the optimized geometry
to the Geometry cell of the new system. Next, Update the Geometry cell of the new system to update
the Results cell of the optimization system (which changed to out of date after the new system is
created and linked) and the Geometry cell of the new system. The Geometry cell of the new system
becomes up-to-date after the action is complete.

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Optimization Analysis Workflow

If you are working with two upstream systems, you simply need to Update the first newly created
system. All other downstream systems share Engineering Data, Geometry, and Model cell data.
Once updated, you can validate all of the systems in one Mechanical session.

Note:

Even though the Geometry cell of the new system is up-to-date, first simplify the optimized
geometry using Discovery Modeling before attempting to open up the geometry in
Mechanical. Attempting to open the unsimplified optimized design from the STL file in
Mechanical will take a long time and will lead to issues due to the use of facets.

2.14.2. Model Validation

Design validation using the Transfer to Design Validation System (Model) option to transfer data
to the downstream system's Model cell. The benefit of this option is that you can automatically
transfer all scoping, loading conditions, etc. to the new system. Follow the steps below to validate
your simulation.

Note:

As desired, you can use non-Ansys tools to validate your design. You will need to retrieve
the STL file of the optimized design in order to import it into the geometry modeling
software of your choice.

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 Performing Design Validation

Create Validation System

To validate your optimized topology, actions are required in Mechanical as well as Workbench.

Important:

• The design validation process does not support Instancing.

• For projects saved prior to release 2026 R1 that are using non-associative CAD import,
the automatic propagation of scoping for the downstream validation system will not
occur. A debug option enables you to correct this situation.

File Preparation in Mechanical

The design validation process requires that you specify a Smoothing object for your desired Topology
Density (p. 88) result in Mechanical. Once you insert the Smoothing object, you need to set the
Export Model property to Yes to make the result available for validation. Evaluate this result object
once complete.

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Optimization Analysis Workflow

The application creates a .pmdb file for export. An example is shown in the File Name property
above. This file is placed in the working project directory and will be used in the creation of the new
design validation system in Workbench.

Note:

The Smoothing feature is not supported for:

• The Linux platform. However, you can create a design validation system on Windows
and then solve it on Linux.

• 2D analyses and analyses that include a 3D Surface Body (Shell).

Create Design Validation System in Workbench

Once you have specified the desired result to export and solved the analysis, return to Workbench.
As shown below, the highlighted context menu option Transfer to Design Validation System
(Model) becomes available to transfer the Results cell of your completed analysis to either the
Geometry cell or the Model cell of a newly created system. To begin this process, right-click the
Structural Optimization's Results cell and select the Transfer to Design Validation System (Model)
option from the menu.

Note:

The operation is the same if you have multiple upstream systems.

Workbench creates and links a new Mechanical system of the same type that is upstream of the
Structural Optimization system.

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 Performing Design Validation

Update New System

As pointed out above, by default, the application creates an .pmdb file for export. In Workbench,
this application generated file becomes available in the drop-down list of the Smoothed Model
property of the Model cell properties on the Workbench Project Schematic. The Smoothed Model
drop-down menu can contain multiple .pmdb files based on the number of Smoothing objects you
specify for export in Mechanical. Multiple files are often created for Topology Density results that
have different Retained Threshold settings.

Next, update the Model cell of the new system: right-click and select Update. This updates the Results
cell of the Structural Optimization system (which changed to out-of-date after the new system is
created and linked) and the Model cell of the new system.

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Optimization Analysis Workflow

Important:

It is possible that you will receive an error during the update. This is a result of a mesh
limitation. Return to Mechanical and specify a Patch Independent Mesh Method and update
the new system again.

If you are working with two upstream systems, you simply need to Update the first newly created
system. All other downstream systems share Engineering Data and Model cell data. Once updated,
you can validate all of the systems in one Mechanical session.

Analyze Optimized Design

Once the Model cell of your new system is up-to-date, you can open it in Mechanical and analyze
the newly optimized topology.

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 Performing Design Validation

If you decide to use Discovery Modeling to adjust the optimized geometry, check the Additive
Manufacturing section (as well as the Designing, Repairing problems, and Preparing designs for
analysis sections) in the Discovery Modeling Help for the tools you can use to simplify and prepare
the optimized geometry in the new system.

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Chapter 3: Design Methods
This chapter examines how each method processes the shapes, the rules you must follow for each
method, as well as other additional general process descriptions.
3.1. Shape Processing Workflows
3.2. Recommendations - Optimization in Practice
3.3. Mixing Multiple Methods within an Analysis
[Link] Optimization versus Shape Optimization

3.1. Shape Processing Workflows

Structural optimization is by nature a large-scale constrained optimization, where the number of degrees
of freedom (DOF) ranges from 1e4 to more than 1e9 and is solved using gradient-based algorithms.

Despite the qualitative differences between the optimization methods, each method follows the same
analytical workflow when performing an analysis, including:

1. Shape Description: For the Shape Optimization and Topography Optimization methods the
shape is explicitly defined using the finite element mesh. The Topology Optimization and Lattice
Optimization methods use implicit descriptions through either density fields (Lattice and Solid
Isotropic Material with Penalization method (SIMP) topology optimization) or level-set functions
(Level Set-based topology optimization).

2. Shape Evaluation: Methods using implicit shape description require dedicated treatment for
finite element analysis.

3. Shape Derivative Computation: Based on the shape description, the application selects how
to best compute the shape derivative, that is, the desired sensitivity for each specified criterion
with respect to the corresponding degrees of freedom of the optimization problem.

4. Shape Update: The application performs final geometry modifications based on the selected
shape description.

See the following sections for the shape processing workflows of each method:
3.1.1. Density Based Topology Optimization Shape Processing
3.1.2. Level Set Based Topology Optimization Shape Processing
3.1.3. Lattice Optimization Shape Processing
3.1.4. Shape Optimization Shape Processing
[Link] Optimization Shape Processing
3.1.6. Materials Optimization Shape Processing

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Design Methods

3.1.1. Density Based Topology Optimization Shape Processing

The density-based method belongs to the family of topology optimization technology. Adopting the
logic of immersed boundary methods, this method aims to optimize the distribution of material
within a working domain by varying a density field ranging from 0 to 1. Topology optimization
technology, which first appeared in the framework of the homogenization method for composites
[1 (p. 349)] [3 (p. 349)]. Simplified approaches, such as Solid Isotropic Material with Penalization method
(SIMP), followed and were devised to force the density to approach either 0 or 1, making them applic-
able for standard solid structures.

Shape Description
You can characterize the density-based approach as a large-scale parametric optimization where the
DOF is the “density.” That is, a unit-less variable ranging from 0 to 1, where:

• A value of zero (0) virtually removes elements to create virtual voids.

• A value of one (1) specifies an element with a material.

As a result, this method does not deliver a shape but an optimized density-field. To create an unam-
biguous design, the application forces the density to approach 0 or 1 and then removes any interme-
diate densities. Here is an example of a part defined with a density-threshold of 0.5 (default).

Where:

(a) is the optimal distribution of density (over the working domain).

(b) is the resulting shape (while drawing the iso-surface corresponding to 0.5 – density)

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 Shape Processing Workflows

Shape Evaluation
For shape evaluation using the density-field, , it is critical to properly update the material
properties. Specifically, the application updates:

• Young modulus and mass for static structural and modal analyses.

• Conductivity and mass for thermal analyses.

To force solutions to approach either zero (0) or one (1), Ansys uses the following widely documented
interpolation schemes:

(linear interpolation for the mass).

(power-law interpolation for stiffness [BS2003]).

Note:

For the above calculations, Mvoid << Msolid and Kvoid << Ksolid correspond to the material
properties of a weak material representing the void.

Shape Derivative
The shape derivative used in gradient-based optimizers for the density-based method is calculated
from the derivative with respect to the density. Furthermore, for:

• Geometric criteria, the computation is analytical.

• Physics-based criteria, the adjoint approach is used.

Shape Update
By adding the descent direction , derived from the gradient-based optimizer, to the current
density field , the application computes a new density field . The calculation is represented
as:

representing the new shape: .

Summary
Degrees of freedom for this method are based on the density of the elements or the density at the
nodes.

Strengths

Enables you to easily manage topological changes.

It is based on the development of light machinery and enables fast convergence.

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Design Methods

Place in Design Stage

Used early in the design process to sketch designs.

Limitations

Can sometimes deliver an ambiguous solution, including intermediate densities that do not
provide the most ideal optimized part.
Produces a less accurate evaluation than the body-fitted approach.

Tips

Use a uniform mesh to equally capture geometric details for the entire domain.

References (p. 349)

[1] MP Bendsoe, N. Kikuchi, Generating optimal topologies in structural design using a homogenization
method, Computer methods in applied mechanics and engineering, 1988.

[2] MP Bendsoe, O. Sigmund, Topology optimization: theory, methods, and applications, Springer
Science & Business Media, 2003.

[3] F. Murat, L. Tartar, Calcul des Variations et Homogeneisation, In Les Methodes de l Homogeneisation
Theorie et Applications en Physique, Coll. Dir. Etudes et Recherches EDF, 57, Eyrolles, Paris, pp.319-
369, 1985.

3.1.2. Level Set Based Topology Optimization Shape Processing

Another topology optimization technology method is the level-set based method. Originally used for
computational fluid dynamics (CFD) to track fluid-interface it is also applied in structural optimization.

Shape Description
This method manages shape description through pure geometric information and defines a shape
without ambiguity. That is, for the shape, defined over the working domain, using an auxiliary function,
denoted as the level-set function, specifies positive, zero, or negative values, such that:

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 Shape Processing Workflows

Note:

• This implicit representation of the shape enables you to make topological changes
without needing to detect topological modifications and reconstruct shape parametriz-
ations.

• Provides a convenient framework for the calculation of geometric quantities, such as

the exterior normal vector: .

• For the level-set functions that provide the same shape description, Ansys uses the
signed-distance function (SDF) [DF2012], defined as:

where denotes the standard Euclidian distance from a point to the

boundary .

• The level-set function is discretized at vertices of the mesh and interpolated inside the
elements.

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Design Methods

Shape Evaluation
The application evaluates the criteria on a fixed mesh. However, the definition of the mechanical
properties is simple and generic, that is:

• Any element lying inside of the shape has a density value of 1.

• Any element lying outside the shape is specified as a void-material.

• As to the one layer of elements cut by the zero level-set, they receive an intermediate density
in accordance with the solid fraction.

Pseudo-density used for the modification of the mechanical properties.

Using the ersatz-material approach [5 (p. 349)], each material property is interpolated as
, where Evoid << Esolid corresponds to the material properties of a weak
material representing the void.

Shape Derivative
The application computes the shape derivative using the continuous formalism defined by Hadamard
(see [5 (p. 349)]). That is, given a shape perturbation , the asymptotic expansion reads:

Where:

is current shape.
is the shape perturbation.
is the new shape.

The shape derivative usually admits the following form:

For the form, the integrand, , depends on the criterion, , through both the solution state
of the mechanical problem and some corresponding adjoint-state.

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 Shape Processing Workflows

Shape perturbation by a vector field .

Shape Update
Given a shape perturbation , the application updates the shape by solving a transport equation for
the level-set function [BDF2012]:

Summary
The degrees of freedom for this method are based on the boundary of the shape.

Strengths

Enables you to easily manage topological changes.

It delivers an unambiguous solution.

Place in Design Stage

Used early in the design process to sketch conceptual designs.

Limitations

Produces a less accurate evaluation that the body-fitted approach.

Due to the heavy machinery, the run is sometimes more expensive compared to the density
method.

Tips

Use a uniform mesh to equally capture geometric details for the entire domain.

References (p. 349)

[4] C. Dapogny, P. Frey, Computation of the signed distance function to a discrete contour on adapted
triangulation, Calcolo, 2012.

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Design Methods

[5] G. Allaire, F. Jouve, AM Toader, Structural optimization using sensitivity analysis and a level-set
method, Journal of computational physics, 2004.

[6] C. Bui, C. Dapogny, P. Frey. An accurate anisotropic adaptation method for solving the level set
advection equation, International Journal for Numerical Methods in Fluids, 2012.

[7] S. Osher, JA Sethian, Fronts propagating with curvature-dependent speed: Algorithms based on
Hamilton-Jacobi formulations, Journal of computational physics, 1988.

3.1.3. Lattice Optimization Shape Processing

This method enables you to compute an optimal variable density lattice distribution in your geometry.

Shape Description
For the lattice method, the working domain is occupied by a lattice structure of varying density .

You need to define the cell-size as well as the minimum and maximum density value
. Based on the values of as well as other options, the product is able to
reconstruct a lattice structure inside of the working domain.

Optimized Lattice Density Distribution

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 Shape Processing Workflows

Lattice Reconstruction

Shape Evaluation
Depending on the lattice pattern and the density value at each element, the mechanical properties
described by the elasticity tensor are modified via analytical formulas [11 (p. 349)], based
on results extracted using the homogenization theory [12 (p. 349)].

Shape Derivative
The shape derivative used in gradient-based optimizers for the lattice method is calculated from the
derivative with respect to the density. Furthermore, for:

• Geometric criteria, the computation is analytical.

• Physics-based criteria, the adjoint approach is used.

The derivatives, , of the elasticity tensor with respect to the density are obtained via analytical
formulas [11 (p. 349)].

Shape Update
By adding the descent direction , derived from the gradient-based optimizer, to the current
density field , the application computes a new density field . The calculation is represented
as:

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Design Methods

Summary
Degrees of freedom for this method are the density at nodes (that will be then mapped at elements).

Strengths

The variable lattice structure is parametrized using just one field.

The computation is fast, thanks to using the homogenized properties in the finite element
analysis.

Place in Design Stage

Used in the final stage of the design process.

Limitations

Some results, such as stress, may not be accurate enough, especially close to the shape boundary,
due to using the homogenized properties in the finite element analysis.

This method only supports linear analyses.

Tips

The smaller you make the lattice cell size, the more accurate the finite element modelling.

References (p. 349)

[11] L. Cheng, P. Zhang, E. Biyikli, J. Bai, J. Robbins, A. To, Efficient design optimization of variable-
density cellular structures for additive manufacturing: theory and experimental validation, Rapid
Prototyping Journal, 2017.

[12] G. Allaire, Homogenization and two-scale convergence, SIAM Journal on Mathematical Analysis,
1992.

3.1.4. Shape Optimization Shape Processing

The Shape Optimization method uses morphing optimization technology to process solid elements
by varying the node locations.

Shape Description

For the Shape Optimization method, the shape is represented by a simplicial mesh
composed of tetrahedral elements .

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 Shape Processing Workflows

Conformal Tetrahedral Mesh

Shape Evaluation
For this method, no special treatment is required to perform shape evaluation.

Note:

An acceptable mesh quality is expected to be retained during the optimization process.

However, excessive deformation of the shape may lead to large approximation errors in
the finite element analysis.

Shape Derivative
The application computes the shape derivative using the continuous formalism defined by Hadamard
(see [5 (p. 349)]). That is, given a shape perturbation , the asymptotic expansion reads:

where:

is current shape.
is the shape perturbation.
is the new shape.

The shape derivative usually admits the following form:

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Design Methods

For the form, the integrand, , depends on the criterion, , through both the solution state
of the mechanical problem and some corresponding adjoint-state.

Shape Perturbation via a Vector Field

Note:

To perform larger shape modifications and to avoid distortions that may lead to poor mesh
quality, the shape gradient is extended inside the whole domain by solving an auxiliary
problem [8 (p. 349)].

Shape Update
The application creates the new shape by updating the position of the mesh vertices using the shape
perturbation , as:

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 Shape Processing Workflows

where:

is the position vector of vertex at the new shape.

is the position vector of vertex at the current shape.
is the shape perturbation.

Specific programming is in place to preserve mesh-quality.

Summary
Degrees of freedom for this method are based on node location.

Strengths

This method accurately computes any state variable given proper mesh quality.

Compared to the topology optimization methods, no numerical trickery occurs to evaluate the
shape.

This method is rather dedicated for local and decent modification, but the implementation has
proved to conveniently manage large shape changes without remeshing.

Place in Design Stage

Used in the final stage of design process when local and decent shape adjustments are expected.

Limitations

Finite element approximation errors could occur due to poor-quality mesh regions or if large
modifications are made.

Because shape optimization does not manages topology changes, additional programming is in
place to preserve mesh-quality. This factor can sometimes lead to additional computational re-
quirements.

Tips

Use a uniform mesh to equally capture geometric details.

References (p. 349)

[8] G. Allaire, C. Dapogny, F. Jouve, Shape and topology optimization, Handbook of numerical analysis,
2021.

[9] G. Allaire, M. Schoenauer, Conception optimale de structures, Springer, 2007.

3.1.5. Topography Optimization Shape Processing

The Topography Optimization method uses morphing optimization technology to process shell ele-
ments by varying the node locations.

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Design Methods

Shape Description

For the Topography Optimization method, the shape, , is represented by a mesh, , and
composed of shell elements . This method is essentially equivalent to the Shape Optimization
method for surface bodies.

Conformal Shell Mesh

Shape Evaluation
For this method, no special treatment is required to perform shape evaluation.

Note:

An acceptable mesh quality is expected to be retained during the optimization process.

However, excessive deformation of the shape may lead to large approximation errors in
the finite element analysis.

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 Shape Processing Workflows

Shape Derivative
The application computes the shape derivative using the continuous formalism defined by Hadamard
(see [AJT2004]). That is, given a shape perturbation , the asymptotic expansion reads:

Where:

is current shape.
is the shape perturbation.
is the new shape.

The shape derivative usually admits the following form:

For the form, the integrand, , depends on the criterion, , through both the solution state
of the mechanical problem and some corresponding adjoint-state.

Shape Update
The application creates the new shape by updating the position of the mesh vertices using the shape
perturbation , as:

Where:

is the position vector of vertex at the new shape.

is the position vector of vertex at the current shape.
is the shape perturbation.

Specific programming is in place to preserve mesh-quality.

Summary
Degrees of freedom for this method are based on node location.

Strengths

This method accurately computes any state variable given proper mesh quality.

Compared to the topology optimization methods, no numerical trickery occurs to evaluate the
shape.

This method is specific to local modifications of the shape but also manages large shape changes
without remeshing.

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Design Methods

Place in Design Stage

Used in the final stage of the design process for local shape adjustments.

Limitations

Finite element approximation errors could occur due to poor-quality mesh regions or if large
modifications are made.

Because shape optimization does not manage topology changes, additional programming is in
place to preserve mesh-quality. This factor can sometimes lead to additional computational re-
quirements.

Tips

Use a uniform mesh to equally capture geometric details.

References (p. 349)

[9] G. Allaire, M. Schoenauer, Conception optimale de structures, Springer, 2007.

[10] M. Shimoda, Y. Liu, A non-parametric free-form optimization method for shell structures, Struc-
tural and Multidisciplinary Optimization, 2014.

3.1.6. Materials Optimization Shape Processing

The materials optimization method aims to optimize the distribution of different materials within a
working domain. For each material a density field that ranges from 0 to 1 is varied. As with Solid
Isotropic Material with Penalization method (SIMP), densities for each material are forced to approach
either 0 or 1, where the sum of the different material’s densities is restricted to equal 1.

Shape Description
You can characterize the materials optimization as a large-scale parametric optimization where the
degrees of freedom (DOFs) are the "densities of each material." Each material has a unit-less variable
ranging from 0 to 1, where:

• A value of zero (0) shows that the material is not present at an element.

• A value of one (1) specifies that an element consists of the material.

As a result, this method does not deliver a shape but an optimized density-field. To create an unam-
biguous design, the application forces the densities to approach either 0 or 1. Moreover, it forces
one, and only one, material to be active in an element.

Shape Evaluation
For shape evaluation, the density-fields of each material, , where n is the number of
materials and is used to properly update the material properties. Specifically, the application updates:

Young modulus and mass for Static Structural analyses.

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 Shape Processing Workflows

To force solutions to approach either zero (0) or one (1), the application uses the following interpolation
schemes:

(linear interpolation for the mass, where is the mass of material i).

(power-law interpolation for stiffness, where represents the stiffness of material i,

and p is the penalization coefficient).

(force one and only one material being active at a time).

Note:

The Void option is considered as a material.

Shape Derivative Computation

The shape derivative used in gradient-based optimizers for the material optimization method is cal-
culated from the derivative with respect to the material densities. Furthermore, for:

• Geometric criteria, the computation is analytical.

• Physics-based criteria, the adjoint approach is used.

Shape Update
The optimizer determines a change in the density field of each material, based on the gradients
of the optimization problem. A new trial design is updated according to:

The density fields of the materials are then used to calculate the material properties of the new design.

Summary
Degrees of freedom for this method are based on the densities of different materials at the elements
or at the nodes.

Strengths

Enables you to easily manage material distribution on domains.

Place in Design Stage

Used early in the design process to sketch designs.

Limitations

Can sometimes deliver an ambiguous solution, including intermediate densities that do not
provide a clear material distribution

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Design Methods

Tip

Use a uniform mesh to equally capture geometric details for the entire domain.

3.2. Recommendations - Optimization in Practice

The available design methods have certain prerequisites, requirements, limitations, and individual features
that you need to understand. Review the following sections as needed for your analysis:
[Link] Optimization - Mixable Density
[Link] Optimization - Level Set Based
3.2.3. Lattice Optimization Analysis
3.2.4. Shape Optimization Analysis
[Link] Optimization
3.2.6. Materials Optimization
[Link] Optimization - Density Based

3.2.1. Topology Optimization - Mixable Density

The mixable-density method is an expanded re-implementation of the density-based method, aiming
to deliver the same capabilities as well as additions to these capabilities.

Furthermore, this development was motivated by the need to:

• Unify and to mutualize some components between all the optimization methods.

• Better align and streamline the density-method within the overall structural optimization
framework.

• Gain consistency between all the optimization methods.

As a result, the mixable-density method:

• Delivers smoother results based on a new numerical scheme.

• Incorporates the benefits of other methods and conversely (cross fertilization process).

• Can be combined with other methods in an optimization problem enabling you to manage
complex systems with dedicated requirements.

Review the following requirements and limitations associated with performing a mixable density-
based optimization analysis. These limitations apply only to the optimization analysis and are not
applicable to any downstream design validation systems. Go to a section topic:

• Element Type Requirements (p. 141)

• General Limitations (p. 141)

• Modal Analysis Limitations (p. 141)

• Linked Static Structural Analysis Limitations (p. 142)

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 Recommendations - Optimization in Practice

Element Type Requirements

The density-based optimization analysis supports Solid elements in the optimization region. The ap-
plication excludes any other element type used in this region from the optimization solution.

General Limitations
The mixable density-based optimization analysis method does not support:

• Imported Plies (Composites).

• Graphical view of Exclusions created by Direct FE boundary conditions.

• Cracks defined within the Fracture object.

• If you specify the Solver Type as Optimality Criteria, the application only supports Response
constraints types of Mass and Volume and Manufacturing Constraints where only the Minimum
Member Size can be specified.

• Use of Section Planes with Topology Density and Topology Elemental Density results. Note that
the User Defined Result does support this feature.

• Pre-stressed Modal analysis.

• Large-deflection effects in a Static Structural analysis (NLGEOM, ON).

• Nonlinear contacts (supported contact includes Bonded and No Separation).

• Axisymmetric model when you wish to define a Global Stress Constraint (p. 62) and Local von-
Mises Stress Constraint. (p. 62)

• Any Thermal system linked to the upstream Static Structural system.

• A solution run on high performance computing (HPC) using Distributed Ansys across multiple ma-
chines, when:

– You have Thermal Condition included in a Static Structural analysis linked to a Structural
Optimization analysis.

– You want to optimize a Static Structural analysis that is linked to an upstream Steady-State
Thermal analysis.

– A Structural Optimization that includes a Reaction Force Constraint.

Modal Analysis Limitations

When linked to a Modal analysis, the mixable density-based optimization analysis does not support:

• Damping when the Damped property set to Yes (and therefore also the Campbell Diagram
chart).

• Unsymmetric solver selection.

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Design Methods

Linked Static Structural Analysis Limitations

When linked to a Static Structural analysis, the mixable density-based optimization analysis does not
support the following boundary conditions:

• Fluid Solid Interface.

• EM Transducer.

3.2.2. Topology Optimization - Level Set Based

The Topology Optimization - Level Set method deals with the boundary of the shapes during the
optimization process. It is a physics driven optimization that is based on a set of loads and boundary
conditions provided by either a single preceding analysis or multiple preceding analyses. Using this
method, the application computes an optimal shape in the design domain that can be applied to a
selected region of your model and that can include specific design objectives and constraints. Here
is an animated example of the Level Set topology optimization method.

The Level Set optimization workflow has some specific considerations as compared to the other
methods, as described below. Use these topics in combination with the general workflow to ensure
the proper completion of your analysis.

Prerequisites and Requirements

All upstream Static Structural and Modal analyses being used in your optimization problem must
already be defined before you solve the optimization analysis

Supported Mesh Elements

Only 3D elements are supported for optimization.

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 Recommendations - Optimization in Practice

Geometric Analysis

For the Objective and the Response Constraint objects, the Level Set method supports the fol-
lowing settings for the Response Type and Response properties:

• Mass

• Volume

• Center of Gravity

• Moment of Inertia

Configuring Static Structural Analysis

Extend Compliance

For the Level Set method when you set the Response Type/Response for the Objective Worksheet
or a Response Constraint object to Compliance, Static Structural analyses supports the combin-
ation of force-based and displacement-based loading as well as thermal loading. This context for
Compliance is described by:

Where:

is the total strain vector.

is the thermal strain vector.

is the elastic strain vector.

is the stress vector.

are the external loads (resp. volume and surface).

are the reaction force and the prescribed displacement.

These formulas are equivalent and are based on the potential energy. The compliance is a self-
adjoint response meaning that no adjoint problem must be solved. The compliance is always
computed over the whole model.

Displacement-based Criterion (will be deprecated and fully replaced by the User Defined Cri-
terion (p. 3))

Context for displacement-based response:

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Design Methods

• For a singular node selection, the response = ( -th node, -axis). You can define
an upper limit for each direction.

• For multiple node selection, the response = (the average of the absolute

displacement along the k-axis).

Note:

When you specify this type of Response Constraint, the Coordinate System
property for the object is read-only and automatically set to Nodal Coordinate
System. The application uses the Global Coordinate System for this setting.

Reaction Force Criterion (will be deprecated and fully replaced by the User Defined Cri-
terion (p. 3))

For a singular node selection, the response = ( -th node, -axis). You can define an
upper limit for each direction.

For multiple node selection, the response = (the RF along the k-axis).

Note:

When you specify this type of Response Constraint, the Coordinate System property
for the object is read-only and automatically set to Nodal Coordinate System. The
application uses the Global Coordinate System for this setting.

Review the Best Practices and Recommendations (p. 145) topic below for additional information
for configuring your upstream analysis.

Configuring Static Structural Analysis

Generalized Thermal Compliance

For the Level Set method when you set the Response Type/Response for the Objective Worksheet
or a Response Constraint object to Thermal Compliance, Steady-State Thermal analyses supports
the combination of Heat Flux, Heat Flow, and Temperature, Convection, and Internal Heat Gener-
ation. This context for Thermall Compliance is described by:

Where:

is the gradient of the temperature.

the isotropic thermal conductivity.

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 Recommendations - Optimization in Practice

the film coefficient and the ambient temperature of the convection condition.
the internal heat generation.
the heat flux.

This is based on the potential energy. The thermal compliance is a self-adjoint response meaning
that no adjoint problem must be solved. The thermal compliance is always computed over the
whole model.

Configuring Modal Analysis

The Level Set method supports Frequency (Eigenfrequency) as the Response/Response Type
setting. Review the Best Practices and Recommendations (p. 145) topic below for additional inform-
ation for configuring your upstream analysis.

Manufacturing Constraint Definition

The Level Set method supports the following Manufacturing Constraint Subtypes (p. 72):

• Member Size (Minimum or Maximum): To properly represent the optimal shape, you
should mesh your model such that Maximum Size of the Member Size is greater than four
times the element average size.

• Pull Out Direction: You can further define the Direction for this constraint: Along Axis
(default), Opposite to Axis, or Both Directions.

Note:

The moldability of the part could be lost during the optimization process.

• AM Overhang Constraint (p. 77): This constraint enables you to further define the Build
Direction and Overhang Angle.

Best Practices and Recommendations

Review the following suggestions when performing this analysis.

Mesh Specifications

When specifying the mesh on your model, it is strongly recommended that you:

• Always use a uniform mesh (homogeneous element size). This enables you to capture the
design with the same precision everywhere on the model. However, in the presence of thin
regions, it may be necessary to refine the mesh locally in order to get at least three or four
layers of elements.

• Make sure that you have a sufficiently fine mesh. If the final design shows geometric features
as thick as an element size, it means that the mesh was not fine enough, as illustrated here.

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Design Methods

This illustration displays 238,000 tetrahedrons on the left and 950,000 on the right. The feature on
the left is very thin (one element size) and reaches the limit of the Level Set capability to properly
capture the design. The finer mesh on the right provides an improved design.

Configuring a Static Structural Analysis

When specifying your upstream Static Structural analysis, note the following:

• A minimum stress problem can be realized by a void design (no material) if there is no stiffness
constraint - if there is no mass, there is no stress. Therefore, Ansys recommends that you use
stress criterion in combination with a stiffness criterion (nodal displacement, compliance, etc.).

• It is strongly encouraged that you specify an "exclusion zone" around the loading conditions
(surface or node-based).

• If your solution experiences disconnected clamped parts, it may be a result of the optimization
aiming to optimally distribute an amount of material. The algorithm sometimes chooses to
save material by disconnecting clamped parts and/or to reinforce others. This characteristic
of optimization is useful in order to identify useful and/or otherwise impractical fixed parts.

Configuring a Modal Analysis

You can control an eigenmode whose frequency always has the same ranking during the optimization
process. If its ranking changes, the algorithm may face some difficulty.

3.2.3. Lattice Optimization Analysis

The Structural Optimization analysis offers a Lattice Optimization Optimization Type. This method
enables you to compute an optimal variable density lattice distribution in your geometry. Use the
following lattice specific topics in combination with the general workflow to ensure the proper
completion of your analysis.

• Lattice Optimization Limitations (p. 147)

• Define Lattice Type, Density, and Cell Size (p. 147)

• Specifying Constraints (p. 148)

• Defining Results (p. 149)

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 Recommendations - Optimization in Practice

• Creating the Lattice Geometry (p. 149)

• Lattice Validation with a Homogenization Model (p. 155)

Lattice Optimization Limitations

In addition to the Topology Optimization - Density Based (p. 168) method limitations, the lattice op-
timization has the following additional limitations. Lattice optimization does not support:

• Nonlinear Contact

• Modes with an Eigenfrequency equal to zero (based on an upstream Modal analysis)

• Thermal Loads

• Export Topology (STL file)

• Local Von-Mises Stress Constraint

• Reaction Force Constraint

• Criterion Constraint

• Member Size

• Pull Out Direction

• Extrusion

• AM Overhang Constraint

• Housing

• For the Octahedral 1 and Octahedral 2 lattice structures, note the following material property lim-
itations:

– A Poisson ‘s Ratio value greater than 0.32 can cause the interpolated material properties to
become inaccurate.

– A low Density value (< 0.05) can generate a negative Young's Modulus value.

Define the Optimization Region Object

Once you have specified the Design Region and the Exclusion Region, set the Optimization Type
property to Lattice Optimization. Once selected, define the following lattice-specific properties.

Category Properties/Options/Description
Lattice Specify the Lattice Type property as one of the following:
Type

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Design Methods

Category Properties/Options/Description
Cubic Crossed
(default)

Midpoint Octahedral
1

Octet Octahedral
2

Diagonal

Minim- Specify a minimum density in order make sure the lattice structures are not too thin.
um The default value is 0.
Dens-
ity
Maxim- Specify a maximum density. The element will be considered as full for densities higher than
um the Maximum Density.
Dens-
ity
Lattice Specify the lattice cell size to be used when rebuilding the lattice geometry for printing.
Cell
Size

Specifying Constraints
For this analysis, the:

• Response Constraint (p. 62) object supports Mass Constraint (default) or Volume Constraint,
Global Stress Constraint, Displacement Constraint, Center of Gravity Constraint, Moment
of Inertia Constraint, Compliance, and Natural Frequency Constraint.

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 Recommendations - Optimization in Practice

• Design Constraint (p. 83) object supports the Symmetry, Pattern Repetition, and Cyclic
Repetition constraints.

Defining Results
Similar to the optimization results (Topology Density (p. 88) and Topology Elemental Density (p. 92)),
lattice optimization supports Lattice Density and Lattice Elemental Density results. These results
produce nodal averaged results and element-based result values. A Lattice Density result object is
inserted automatically. You can add additional objects by selecting Lattice Density or Lattice Ele-
mental Density from the Result group on the Solution context tab or by right-clicking the Solution
folder (or in the Geometry window) and selecting Insert > Lattice Density/Lattice Elemental
Density.

Result Display Feature

A lattice analysis automatically inserts a Lattice Density Tracker as a child object of the Solution
Information object that enables you to view the optimization of the model during the solution.

Results Display Limitations

These result types do not support some of the display options available from the Geometry drop-
down menu on the Result Context tab, including Exterior, IsoSurfaces, and Capped IsoSurfaces.

Creating the Lattice Geometry

To make the optimized results available to a downstream geometry system, you need to create the
new system on the Workbench Project Schematic and link the Results cell of your lattice optimization
analysis to the Geometry cell of a new downstream system, either a Geometry component system
or the Geometry cell of another analysis system. An example of this configuration is illustrated below.

The lattice type, cell size, and density information are automatically transferred when linking a lattice
optimization analysis to a Geometry system. Opening your new lattice geometry in the Discovery
Modeling application enables you to further modify aspects of your geometry.

Procedure

1. From the Workbench Project Schematic, create a new downstream Geometry system, as illus-
trated below.

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Design Methods

2. Link the Results cell of your lattice optimization analysis to the Geometry cell of the downstream
system.

3. Right-click the Results cell of your lattice optimization analysis and select Update.

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 Recommendations - Optimization in Practice

4. Right-click the Geometry cell of the downstream system and select Refresh.

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Design Methods

5. Right-click the Geometry cell of the downstream system and select Update.

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 Recommendations - Optimization in Practice

6. Open Discovery Modeling from the Geometry cell of the downstream system.

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Design Methods

7. In SpaceClaim, select Shell tool from the Facets tab.

8. From the Shell Options tool, 1) choose Basic as the Infill type, and then 2) select the Solid body
in the structure tree, and then 3) select Use Density Attributes. The Lattice Shape from the drop-
down menu is automatically chosen. This includes the lattice type you specified in the optimization
analysis in Mechanical.

Note:

Using the Select Faces or Facets tool (highlighted below) from the design window,
you can choose to selectively exclude faces from the original body from this outer

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 Recommendations - Optimization in Practice

shell. This enables the lattice infill to extend all the way to the boundary of the part
on that face.

9. A green check mark in the design window verifies the operation. The density distribution from
the lattice optimization is now mapped onto the body and a faceted body is generated.

Lattice Validation with a Homogenization Model

For a Lattice Optimization analysis, the steps to create a downstream validation are slightly different
than for the other optimization methods available in the application.

Note:

For the upstream system, the Output Controls property Export Knockdown Factor must
be set to Yes. This is the default setting.

Duplication

When you use the Duplicate option on the Solution cell, you include all (loading, results, etc.)
objects defined in the upstream system.

1. Right-click the Solution cell of the upstream system and select Duplicate. A new system
is placed into the schematic. This new system includes all environmental conditions
defined in the upstream system, such as loading conditions or results.

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Design Methods

2. Drag and drop the Solution cell of the Structural Optimization analysis onto the Setup
cell of the new system. The application properly links the systems together.

3. Right-click the Setup cell of the new system and select Update. Your new system is ready
for a validation analysis.

Transferring Data

You can also use the system option Transfer Data To New. When used, none of the environmental
conditions defined in the upstream system, such as loading conditions or results are included in
the new system. The steps to use this method are described below.

1. Right-click the Solution cell of the Structural Optimization analysis and select Transfer
Data to New > Analysis System type.

A new system in inserted and is linked accordingly.

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 Recommendations - Optimization in Practice

2. Right-click the Setup cell of the new system and select Update. Your new system is ready
for a validation analysis.

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Design Methods

3.2.4. Shape Optimization Analysis

Introduction
The Shape Optimization option of the Optimization Type property enables shape optimization
using mesh node relocations. As with the other optimization methods, this is a physics driven optim-
ization based on a set of loads and boundary conditions provided by either a single preceding ana-
lysis or multiple preceding analyses.

Using this method, the application computes an optimal shape in the design domain that you can
apply to a selected region of your model and that also includes specific design Objectives and Con-
straints.

Upstream System Recommendations

Review the following to properly prepare your upstream systems. Shape Optimization has the same
capability as the Level Set method. Any differences are mentioned when necessary.

Geometric Analysis

Review the Geometric Analysis (p. 143) topic in the Prerequisites and Requirements content in the
Topology Optimization - Level-Set Based section for the supported Response Type and Response
properties when performing a geometric analysis.

Static Structural Analysis

Review the Configuring Static Structural Analysis (p. 143) topic in the Prerequisites and Requirements
content in the Topology Optimization - Level-Set Based section for the supported Response
Type/Response for the Objective Worksheet or a Response Constraint object to Compliance.
Static Structural analyses supports the combination of force-based and displacement-based
loading as well as thermal loading.

In addition, when specifying your upstream Static Structural analysis, note that any surface of the
optimizable body that is scoped to boundary conditions (fixed displacements, loads, bonded
contacts, etc.) must be defined in the Exclusion Region.

Modal Analysis

This method supports Frequency (Eigenfrequency) as the Response/Response Type setting.

In addition, when specifying your upstream Modal analysis, note that you can control an eigenmode
whose frequency always has the same ranking during the optimization process. If its ranking
changes, the algorithm will face some difficulty.

Manufacturing Constraint

For this analysis method, only the Member Size (Maximum) property is available. To properly
represent the optimal shape, you should mesh your model such that Maximum Size of the
Member Size is greater than four times the element average size.

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 Recommendations - Optimization in Practice

Application Differences
Note the following when using the Shape Optimization method.

Specifying the Mesh

This analysis method supports 3D tetrahedron solid elements only in the Optimization Region -
all other element types are excluded.

Important:

When specifying the mesh on your model, it is strongly recommended that you:

• Always use a uniform mesh (homogeneous element size). This enables you to
capture the design with the same precision everywhere on the model.

• Make sure that you have a sufficiently fine mesh.

Specifying Optimization Type

You use the Optimization Region object to select a region of your geometry on which to perform
optimization as well as the optimization method to be used.

1. In order to scope the optimization regions using the Shape Optimization method, you need
to first generate the mesh.

2. Specify the Design Region. The properties of the Design Region category enable you to
define the geometry as a Geometry Selection or a Named Selection. This is the region that
you wish to optimize.

3. Specify the Exclusion Region. The properties of the Exclusion Region category enable you
to specify a region (geometric entities or elements) to be excluded from optimization. You
specify excluded regions using defined Boundary Conditions, Geometry Selection, or a Named
Selection.

The surfaces scoped to boundary conditions (such as Fixed Support, Force, Bonded Contact,
etc.) must be included in the scoping of the Exclusion Region.

Note:

Bordering the scoping of your defined Exclusion Region is a "buffer zone." The
area is a transition region where the deformation is less permissive. This enables a
smoother result.

4. Set the Optimization Type property to Structural Optimization. Specify the following addi-
tional properties as needed:

• Move Limit Per Iteration: This property enables you to define how far each node can
move at each iteration. It must be defined in length units, such as one element size.

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Design Methods

By default, this property is set to Program Controlled. Select the Manual option to
change the value.

Note:

Ansys recommends that you use a value smaller than the average ele-
ment size and smaller than the Total Move Limit property setting.

• Total Move Limit: This property enables you to define how far each node can move
in total. It must be defined in length units, such as three element sizes. By default, this
property is set to Program Controlled. Select the Manual option to change the value.

• Mesh Deformation Control: This property enables you to define how much the mesh
can be stretched. It is an additional control to avoid element distortion. This unit-less
value is a sort of penalty factor that ranges from 0 (no control) to 1.0. By default, this
property is set to Program Controlled. Select the Manual option to change the value.

Note:

When you use the Program Controlled setting, a new value is computed that is
based on the number of layers of elements in the mesh. As a result, the more layers
you have, the more permissive the tuning. This means that the Total Move Limit
will be higher, and the Mesh Deformation Control will be smaller.

Specifying Results

This method supports Topology Density results. The Topology Density object (p. 88) is added
automatically to the analysis system. You can add additional objects by selecting Topology
Density from the Results group on the Solution Context tab or by right-clicking the Solution
folder (or in the Geometry window) and selecting Insert>Topology Density.

Here is an example of an optimized result.

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 Recommendations - Optimization in Practice

3.2.5. Topography Optimization

The Topography Optimization option of the Optimization Type property enables shape optimization
using mesh node relocations. As with the other optimization methods, this is a physics driven optim-
ization based on a set of loads and boundary conditions provided by either a single preceding ana-
lysis or multiple preceding analyses.

Compared to Shape Optimization, Topography Optimization is used for shell-based models only.

Using this method, the application computes an optimal shape in the design domain that you can
apply to a selected region of your model and that also includes specific design Objectives and Con-
straints.

Upstream System Recommendations

Review the following to properly prepare your upstream systems. Topography Optimization has the
same capability as the Shape Optimization method. Any differences are mentioned when necessary.

Geometric Analysis

Review the Geometric Analysis topic in the Prerequisites and Requirements content in the
Topology Optimization - Level-Set Based (p. 142) section for the supported Response Type and
Response properties when performing a geometric analysis.

Only Mass and Volume are available.

Static Structural Analysis

Review the Configuring Static Structural Analysis topic in the Prerequisites and Requirements
content in the Topology Optimization - Level-Set Based (p. 142) section for the supported Response
Type/Response for the Objective Worksheet or a Response Constraint object.

In addition, when specifying your upstream Static Structural analysis, note that any surface of the
optimizable body that is scoped to boundary conditions (fixed displacements, loads, bonded
contacts, etc.) must be defined in the Exclusion Region.

Modal Analysis

This method only supports User Defined Criterion (p. 3) that you define in the upstream Modal
analysis. This result data can then be used in the Structural Optimization analysis by the Objective
object or as a Response Constraint .

In addition, when specifying your upstream Modal analysis, note that you can control an eigenmode
whose frequency always has the same ranking during the optimization process. If its ranking
changes, the algorithm will face some difficulty.

Manufacturing Constraint

For this analysis method, no manufacturing constraint are yet available

Application Differences
Note the following when using the Topography Optimization method.

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Design Methods

Specifying the Mesh

This analysis method supports triangle and quadrangles.

Important:

When specifying the mesh on your model, it is strongly recommended that you:

• Always use a uniform mesh (homogeneous element size). This enables you to
capture the design with the same precision everywhere on the model.

• Make sure that you have a sufficiently fine mesh.

Specifying Optimization Type

You use the Optimization Region object to select a region of your geometry on which to perform
optimization as well as the optimization method to be used.

1. In order to scope the optimization regions using the Topography Optimization method, you
need to first generate the mesh.

2. Specify the Design Region. The properties of the Design Region category enable you to
define the geometry as a Geometry Selection or a Named Selection. This is the region that
you wish to optimize.

3. Specify the Exclusion Region. The properties of the Exclusion Region category enable you
to specify a region (geometric entities or elements) to be excluded from optimization. You
specify excluded regions using defined Boundary Conditions, Geometry Selection, or a Named
Selection.

The surfaces scoped to boundary conditions (such as Fixed Support, Force, Bonded Contact,
etc.) must be included in the scoping of the Exclusion Region.

4. Set the Optimization Type property to Topography Optimization. Specify the following
additional properties as needed:

• Move Limit Per Iteration: This property enables you to define how far each node can
move at each iteration. It must be defined in length units, such as one element size.
By default, this property is set to Program Controlled. Select the Manual option to
change the value.

• Total Move Limit: This property enables you to define how far each node can move
in total. It must be defined in length units, such as three element sizes. By default, this
property is set to Program Controlled (equal to the size of one element or slightly
larger depending the fineness of the mesh). Select the Manual option to change the
value.

• Mesh Deformation Control: This property enables you to define how much the mesh
can be stretched. It is an additional control to avoid element distortion. This unit-less
value is a sort of penalty factor that ranges from 0 (no control) to 1.0. By default, this
property is set to Program Controlled. Select the Manual option to change the value.

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 Recommendations - Optimization in Practice

Specifying Results

This method supports Topology Density (p. 88) results. The Topology Density object is added
automatically to the analysis system. You can add additional objects by selecting Topology
Density from the Results group on the Solution Context tab or by right-clicking the Solution
folder (or in the Geometry window) and selecting Insert > Topology Density.

3.2.6. Materials Optimization

This method enables you to determine the optimal distribution of different materials in one domain.
The mixable density-based performs optimization based on the density of each element. The applic-
ation creates a unique nodal field where the density is forced to approach either 0 or 1 rather than
varying continuously. In contrast, this method generates one field that distributes one or more mater-
ials throughout the specified design space.

Points to Remember
Note the following before beginning your analysis:

• Use the Engineering Data Workspace to create specific materials. Engineering Data is a component
of the Workbench application. To use the workspace, you must create or resume your analysis from
the Workbench Project Schematic.

• You can add materials to your project using the Materials object.

• You can import materials from an external library file into your project.

• When performing an optimization with multiple materials, Ansys recommends that you use mater-
ials with significantly different properties. Similar material properties increase the risk of creating
problems that do not have a feasible solution.

• Applying multiple Local Design Restriction objects that include different materials to the same region
can create infeasible problems.

• This method enables you to perform lattice optimization. All of the requirements, limitations, and
definition specifics Lattice Optimization Analysis (p. 146) are applicable.

Important:

– You can specify the analysis to use only material distribution (Full) or lattice distribu-
tion. These capabilities cannot be combined.

– Lattice optimization only supports the use of one material.

– Because of processing differences, results for lattice structures evaluated using this
method may differ form those you receive using the Lattice Optimization method.

• Use a uniform mesh to equally capture geometric details for the entire domain.

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Design Methods

Limitations

• When you change the Optimization Type property to Materials Optimization, the worksheet
for material definition may not automatically refresh or display. To resolve this issue, you need
to select any other object in the Outline and then return to the Optimization Region object.
This action will properly display the worksheet.

• When using Full Screen mode, you could see an issue when changing the options of the Filling
Method drop-down menu of the worksheet. Exit Full Screen mode to correct the issue.

Definition
You can define the analysis for the following:

• Multiple Materials (p. 164)

• Lattice (p. 165)

Multiple Materials

This procedure assumes that you have opened the application, defined your upstream analysis,
and inserted a Structural Optimization analysis. To define an analysis using the Materials Op-
timization method:

1. Select the Materials Optimization option for the Optimization Type property, a worksheet
automatically displays.

2. Use the Materials drop-down menu of the worksheet to select the desired material. If you
wish to use the Void option, it must be specified first. This option behaves as material selection
but gives the application the option to not use material in the design space.

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 Recommendations - Optimization in Practice

3. Select Full from the Filling Method drop-down menu. Full is the only supported option to
perform material distribution. To perform a lattice optimization, see the topic below.

Note:

If you are working with a project that was originally saved in release 2025
R1, the application sets the Filling Method property of the Materials Optim-
ization method to Lattice. This is a result of lattice only support in release
2025 R1 but not multiple materials optimization. Change this setting as
needed.

4. Specify additional materials as desired.

Lattice

1. Select the Materials Optimization option for the Optimization Type property, a worksheet
automatically displays.

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Design Methods

2. Use the Materials drop-down menu of the worksheet to select the desired material. The
Lattice feature only supports the use of one material.

3. Select Lattice from the Filling Method drop-down menu.

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 Recommendations - Optimization in Practice

4. Under Lattice Specifications table, the selected material displays automatically with default
settings for the Lattice Type, Minimum Density, and Maximum Density properties.

Note:

These are the same properties that display in the Details pane when you specify
the Lattice Optimization method for the Optimization Type property of the
Optimization Region object. However, the application does not specify default
values for the Maximum Density property and a Lattice Cell Size property is also
available using this method.

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Design Methods

5. Select a desired Lattice Type and then specify the Minimum Density and Maximum
Density properties.

6. See the Lattice Optimization Analysis (p. 146) section for additional details for completing
your simulation using the lattice-based method.

3.2.7. Topology Optimization - Density Based

Review the following requirements and limitations associated with performing a density-based optim-
ization analysis. These limitations apply only to the optimization analysis and are not applicable to
any downstream design validation systems. In addition, see the next section, Topology Optimization
- Density Based Solution Methodology (p. 170), for a description of the theory behind the solution
methodology used for density-based optimization analyses.

• Element Type Requirements (p. 168)

• Recommendations (p. 168)

• General Limitations (p. 168)

• Modal Analysis Limitations (p. 169)

• Linked Static Structural Analysis Limitations (p. 169)

• Linked Thermal Analysis Limitations (p. 169)

Element Type Requirements

The density-based optimization analysis supports Solid, Shell, and Plane elements in the optimization
region. The application excludes any other element type used in this region from the optimization
solution.

Recommendations
For a density-based optimization analysis, Ansys recommends that you:

• Use the mixable density method when you specify a Thermal Condition in an upstream
Static Structural analysis to enable a more versatile and robust problem formulation.

General Limitations
The density-based optimization analysis method does not support:

• Imported Plies (Composites).

• Graphical view of Exclusions created by Direct FE boundary conditions.

• Cracks defined within the Fracture object.

• If you specify the Solver Type as Optimality Criteria, the application only supports Response
constraints types of Mass and Volume and Manufacturing Constraints where only the Minimum
Member Size can be specified.

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 Recommendations - Optimization in Practice

• Use of Section Planes with Topology Density and Topology Elemental Density results. Note that
the User Defined Result does support this feature.

• Pre-stressed Modal analysis.

• Large-deflection effects in a Static Structural analysis (NLGEOM, ON).

• Nonlinear contacts (supported contact includes Bonded and No Separation).

• Axisymmetric model when you wish to define a Global Stress Constraint (p. 62) and Local von-
Mises Stress Constraint. (p. 62)

• Any Thermal system linked to the upstream Static Structural system.

• A solution run on high performance computing (HPC) using Distributed Ansys across multiple ma-
chines, when:

– You have Thermal Condition included in a Static Structural analysis linked to a Structural
Optimization analysis.

– You want to optimize a Static Structural analysis that is linked to an upstream Steady-State
Thermal analysis.

– A Structural Optimization that includes a Reaction Force Constraint.

Modal Analysis Limitations

When linked to a Modal analysis, the density-based optimization analysis does not support:

• Damping when the Damped property set to Yes (and therefore also the Campbell Diagram
chart).

• Unsymmetric solver selection.

• Optimality Criteria solver selection.

Linked Static Structural Analysis Limitations

When linked to a Static Structural analysis, the density-based optimization analysis does not support
the following boundary conditions:

• Joint Load.

• Fluid Solid Interface.

• EM Transducer.

Linked Thermal Analysis Limitations

For a density-based optimization analysis linked to an upstream Steady State Thermal analysis, the
application does not support the use of the Ansys Remote Solve Manager (RSM) to submit jobs on a
remote machine.

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Design Methods

[Link]. Topology Optimization - Density Based Solution Methodology

Review the following for the theory behind the solution methodology for density-based optimization
analyses:

• Sequential Convex Programming (p. 170)

• Optimality Criteria (p. 170)

• Solution Methodology for Natural Frequencies (p. 171)

• Solution Methodology for Stress Constraints (p. 172)

• Solution Convergence Criteria (p. 173)

• Topology Optimization with Thermal Condition (p. 173)

• References Materials (p. 174)

Sequential Convex Programming

The Sequential Convex Programming method (SCP), see Zillober[1][2][3], is an extension of the
method of moving asymptotes (MMA), see Svanberg[4]. The Sequential Convex Programming
method requires the derivatives of all functions present in the Topology Optimization problem.
MMA is a nonlinear programming algorithm that approximates a solution for a Topology Optimiz-
ation problem by solving a sequence of convex and separable subproblems. These subproblems
can be solved efficiently due to their special structure.

The Sequential Convex Programming method extends MMA to ensure convergence by rejecting
steps that do not lead to an optimal solution of the underlying problem. The test for acceptance
is done by a merit function and a corresponding line search procedure, see Zillober[5]. The goal of
the merit function is to measure the progress and enable the objective function and the constraints
to be combined in a suitable way.

Optimality Criteria
The Optimality Criteria method can be used to solve density-based optimization problems with a
simple compliance objective that uses a volume or mass constraint. The Optimality Criteria method

[1] Zillober, Ch., A globally convergent version of the method of moving asymptotes, Structural
Optimization, 6(3):166-174, 1993.
[2] Zillober, Ch., A combined convex approximation — interior point approach for large scale
nonlinear programming, Optimization and Engineering, 2(1):51-73, 2001.
[3] Zillober, Ch., SCPIP - an efficient software tool for the solution of structural optimization
problems, Structural and Multidisciplinary Optimization, 24(5), 2002.
[4] Svanberg, K., The Method of Moving Asymptotes — a new method for structural optimiza-
tion, International Journal for Numerical Methods in Engineering, 24:359-373, 1987.
[5] Zillober, Ch., Global convergence of a nonlinear programming method using convex approx-
imations, Numerical Algorithms, 27(3):256-289, 2001.

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 Recommendations - Optimization in Practice

is an iterative solver, see Bensoe and Sigmund[6]. The Optimality Criteria method should not be
used for a Modal Analysis.

Note:

The following limitations apply when using the Optimality Criteria Solver Type:

• Only supports the Compliance (Structural) setting for the Response Type column
of the Objective object worksheet.

• Only Volume and Mass constraints are supported.

• The Manufacturing Constraint is supported where only the Minimum property

for the Member Size constraint subtype can be specified.

Solution Methodology for Natural Frequencies

When performing density-based optimization analysis with supported natural frequencies, you can
specify the frequency as either an objective or as a constraint. A single natural frequency or a
weighted combination of several natural frequencies can be defined using the Objective object.
The aim of the optimization is to maximize these frequencies according to their weights (as defined
in the Worksheet).

In addition, you can add a single natural frequency as a constraint and define a lower and an upper
bound on the frequency. The solver will guarantee, if possible, that this frequency lies within the
specified range.

If the design objective is to optimize a frequency, then all of the repeating frequencies are optimized
simultaneously.

It is important to note that the mode shapes will change during the iterative solution procedure
and that there is no tracking with respect to the initial mode shape. Only the actual value of the
specified natural frequency is considered. This means at the final iteration the mode shape may
change dramatically in comparison to the initial shape of the optimized mode.

Because the underlying solver is sensitivity based, problems with natural frequencies have to be
handled with care. The problem is not differentiable in the common sense, such as a case of multiple
eigenvalues. Instead, derivatives for multiple eigenvalues have to be calculated in a special way.
Since the mode shapes are not unique for multiple eigenvalues, additional effort is necessary to
get sensitivities that are independent of the mode shapes. In order to obtain unique sensitivities
for these eigenvalues, an additional eigenvalue problem has to be solved for each optimized element,
see Seyranian[7].

[6] Bendsoe, M.P. and Sigmund O., Topology Optimization: Theory, Methods and Applications,
Springer, Berlin, 2003.
[7] Seyranian, A.P., Lund E., and Olhoff N., Multiple eigenvalues in structural optimization
problems, Structural Optimization, 8:207-227, 1994.

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Design Methods

Solution Methodology for Stress Constraints

When working with topological optimization for global stress constraints, and local stress constraints
applied to more than one element, you can specify an upper bound on the stress that has to be
satisfied by all elements. Theoretically, this requires the solution of an optimization problem with
n stress constraints, where n denotes the number of optimized elements taken into account. Because
the computational effort would be too great to achieve this, a relaxed reformulation has to be ap-
plied. In order to keep the complexity of the optimization problem low, a set of elements is repres-
ented by one constraint instead of individual ones. This technique divides the original design space
into clusters. The maximum stress value with respect to all elements in the cluster/set S has to
satisfy the following:

Where is the elemental mean value of the equivalent (von-Mises) stress of element e in set S.
Since the maximum leads to a non-differentiable problem formulation, the p-norm is used to ap-
proximate the actual maximum instead. Applying the differentiable p-norm leads to:

Where denotes the vector of all stress values of the elements in set S. Note that the p-norm
overestimates the actual maximum. To stabilize the solver different regularization techniques are
used in the literature. In Holmberg[8], a fixed scaling parameter is introduced. With factor:
that leads to:

where nS is the number of elements in the considered set. In previous releases this approach was
used. Since at the final iteration, the maximum stress of some optimized elements might be
greater than the user-defined upper bound of the global/local stress constraint, the validation
might fail.

To improve the accuracy of the approximation, a different regularization techniques is available. In

Le[9], the nnormalized maximum approximation is used to measure the stress value of a cluster/set.
Here the p-Norm is also applied but instead of using a fixed factor an adaptive factor is introduced.
In each iteration the factor is modified. This technique leads to:

Where denotes the iteration. This approach improves accuracy as well as the estimate of the stress
value.

[8] Holmberg E., Torstenfelt B., and Klarbring A., Stress constrained topology optimization,
Structural and Multidisciplinary Optimization, 48(1):33-47,2013.
[9] Le C., Norato J., Bruns T., Ha C., Tortorelli D. Stress-based Topology Optimization for continua,
Structural and Multidisciplinary Optimization, 41(4):605{620, 2010.

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 Recommendations - Optimization in Practice

Solution Convergence Criteria

The density-based optimization solver approaches a stationary point where all constraints are sat-
isfied within a tolerance of 0.1 percent of the defined bound. This tolerance is defined by the
Convergence Accuracy property (see Specify Analysis Settings (p. 24)).

To simplify the notation, assume that only one constraint exists. The optimality conditions of the
Topology Optimization problem can be stated with the following equation:

Where denotes the Lagrange function. The Lagrange function is defined by:

Where is the Lagrange multiplier corresponding to the constraint , and is the objective function
to be either maximized or minimized. The solver will stop as soon as the desired tolerance is
achieved, where: , as defined here:

Because approaching this stationary point can require a large number of iterations, a relaxed con-
vergence criterion is used. The optimization stops as soon as the following equation has three
successive iterations. In this equation, denotes the vector of pseudo densities of the iteration.

Note that three successive iterations are considered as the underlying solver is stabilized by a line
search procedure. This line search procedure might lead to small changes with respect to the pseudo
densities as well as small changes to the objective function. It is possible that the convergence
tolerance is satisfied for one iteration but the next iteration leads to a significant improvement of
the objective function. Due to the relaxed stopping criterion, the optimization might terminate too
early. In this case, the optimization should be rerun with a smaller tolerance.

Topology Optimization with Thermal Condition

The optimization is influence by the thermal condition according to the following equation[10]:

Linear static equilibrium in finite element system including both mechanical and thermal loading
is given by:
,

Where:

= stiffness matrix

[10]JoshuaD. Deaton, Ramana V. Grandhi: "Stress-based Topology Optimization of Thermal

Structures",10th World Congress on Structural and Multidisciplinary Optimization, 2013,
Orlando, Florida, USA.

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Design Methods

= displacement vector
= externally applied mechanical loading
= thermal load vector.

The nodal load vector due to temperature effects for the element may be written as:

Here is the element strain-displacement matrix, is the element elasticity matrix, and is
the thermal strain vector for the element given by:

With is the thermal expansion coefficient of the material, is the temperature change on
the element, and is [1,1,1,0,0,0] for three-dimensions and [1,1,0] for two-dimension.

References

3.3. Mixing Multiple Methods within an Analysis

Using multiple Optimization Region objects, you can combine the following optimization methods
within an optimization problem.

Note:

The Materials Optimization method cannot be mixed with other design methods. Only one
Optimization Region object is supported for this method.

Density Lattice Level Set Mixable Shape Topography

Based Optimization Based Density Optimization Optimization
Optimization Optimization
Density Based X
Optimization
Lattice Optimization X
Level Set Based X X X X
Optimization
Mixable Density X X X X
Shape Optimization X X X X
Topography X X X X
Optimization

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 Topology Optimization versus Shape Optimization

3.4. Topology Optimization versus Shape Optimization

Topology Optimization methods (Density and Level Set) relate to the Immersed Boundary Method
(I.B.M.) in that the shape is approximated using an auxiliary field (density-field or level-set function).
Using this method, the application fixes the mesh during the optimization process and optimizes the
shape by distributing the material layout within a given design domain. Topology Optimization is very
convenient when you expect significant changes (hole nucleation, merge of members, etc).

Shape Optimization methods relate to a body-fitted method in that the shape is explicitly defined by
the mesh. Using this method, the application optimizes the design by moving the mesh nodes. Shape
Optimization is a sort of morphing without the need to define any parameter. By contrast to Topology
Optimization, the calculation of certain quantities, such as stress, is more accurate. Shape Optimization
is convenient when you expect moderate modifications while keeping the same topology (no hole, no
merge).

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Chapter 4: Structural Optimization Theory
In order to provide background about how manufacturing and design constraints are implemented
and the options you can use to further improve your results, this section describes the concepts behind
the use of the constraints in the application when performing a Structural Optimization analysis.

Important:

For the examples in the following sections, the results you obtain may differ slightly from
those shown, depending on the version of the application you are using.

Go to a section topic:
4.1. Manufacturing Constraint Background
4.2. Design Constraints Background
4.3. Local Design Restrictions

4.1. Manufacturing Constraint Background

Structural optimization often results in complex shapes that are difficult to realize under specific manu-
facturing processes. Incorporating manufacturing constraints in the setup of the optimization problem
can help to reduce and even eliminate manual post-processing, speed-up the design process, and ensure
optimality of the final shape.

However, manufacturing constraints also include limitations related to the numerical framework (Optim-
ization Method, Optimization Region, Mesh, etc.). The following documentation discusses the basic
details of their formulation and numerical implementation together with limitations and best-practices
for efficient usage.

Note:

The description "average element size," denoted dxAVG, appears frequently in the numerical
implementation of manufacturing constraints. For 3D solid domains, the average element
size is defined as the average of the cubic root of the volume over all elements.

Go to a section topic:
4.1.1. Member Size Minimum
4.1.2. Member Size Maximum
4.1.3. Member Size Gap Size
4.1.4. Pull Out Direction
4.1.5. Millability

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Structural Optimization Theory

4.1.6. Extrusion
4.1.7. AM Overhang Constraint
4.1.8. Housing
4.1.9. Complexity Index

4.1.1. Member Size Minimum

The Minimum property prevents the formation of thin features in the optimized shape.

Industry Motivation
This specification is motivated by several industrial manufacturing processes. Examples include:

• During a casting process, you can actively avoid thin areas in the mold that can lead to failure
as a result of premature solidification.

• During an additive manufacturing process, you can avoid thin members that can result in im-
perfections in the printing process.

Member Size Minimum Definition

In theory, the computation of the minimum member size is performed in two steps:

1. The application computes the cross-sectional thickness for every point on the boundary, that
is, the distance until crossing the opposite boundary along the direction opposite to the ex-
terior normal vector.

2. The minimum value of the distance field is defined as the minimum member size of the
structure.

For example, in the wall-type example, the cross-sectional length equals:

• Length (X-direction)

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 Manufacturing Constraint Background

• Width (Y-direction)

• Height (Z-direction)

Plate Structure Cross-sectional Length

This formulation has two main drawbacks:

• It is not derivable due to the minimum operator, and therefore not suitable for gradient-based
optimization algorithms.

• It is not applicable for all methods, namely it requires geometric information that is not available
for density-based methods.

The Minimum Member Size constraint is available for density-based optimization, mixable density,
and level-set based optimization. The formulation depends on the structural optimization framework.

Density and Mixable Density Level-Set

Built-in approach based on filtering The theoretical definition is adopted, based on the
techniques [2 (p. 349)]. cross-sectional thickness, and is appropriately adjusted to
overcome the differentiability issue [13 (p. 349)].

Setup and Technical Specifications

The setup only requires specifying the lower limit not to violate, denoted , in terms of length
units.

Density Based Mixable Density Level Set Based

Note: Note:

is is
automatically automatically
rounded-up rounded-up
to . to .
The The
default default
value is value is
equal

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Structural Optimization Theory

Density Based Mixable Density Level Set Based

equal to to 4
. .

Exclusion You specify whether Exclusion regions are inherently considered in the
Region to Include or Exclude member size evaluation.
Exclusions from the
Analysis Settings.
Infeasible Naturally ignored Detected and eliminated from
[a] the constraint evaluation.
Regions
Special None The optimization runs first
treatment without the MinMS constraint.
If the solution does not meet
the requirement, then the
optimization continues adding
the MinMS as a constraint.
Mesh The finer the mesh, the more accurate the computations related to Minimum
Size member size.
[a] Regions where the Minimum Member Size cannot be respected - closely spaced boundaries.

Recommendations
Note the following:

• The computational time for the Minimum Member Size constraint increases together with
and the mesh size refinement.

• As any constraint, the Minimum Member Size affects the objective performance. Namely, by
increasing , the feasible domain shrinks and probably leads to smaller objective gain. Es-
pecially when an objective function with antagonistic behavior is used, that is, the volume,
this tendency becomes more significant.

Example
For the following example, the Optimization Type property is set to the Topology Optimization –
Level Set Based option. The optimization problem consists of:

• Minimizing the structural compliance under a volume fraction constraint of 0.4.

• A Maximum Member Size constraint with dmax = 1.0e-02.

• A Pull-Out Direction constraint in the Z-direction.

• A Cyclic Repetition Design Constraint with 4 sectors enforced.

Example File

Download the following project file to examine the feature in more detail:

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 Manufacturing Constraint Background

Project File (Member_Size_Minimum_Engine_Bracket.wbpz):

Set Up and Mesh

The upstream Static Structural system is specified with two displacements, a force, and a moment,
as illustrated.

The finite element mesh includes 153,729 elements.

No Minimum Member Size

As shown from the Topology Density as well as a User Defined Result, the optimized result without
considering an minimum member size constraint, shown here, produces slender "ribs.". Note that the
User Defined Result shown below is a cutout of the result using the Section Plane feature.

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Structural Optimization Theory

Include Minimum Member Size

When you add a minimum member size constraint with dmin = 8.0e-03, it leads to the optimized
shape where slender ribs disappear.

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 Manufacturing Constraint Background

References (p. 349)

[3] M.P. Bendsoe, O. Sigmund. Topology optimization: theory, methods, and applications, Springer
Science & Business Media, 2003.

[13] G. Allaire, F. Jouve, G. Michailidis, Thickness control in structural optimization via a level set
method, Structural and Multidisciplinary Optimization, 2016.

4.1.2. Member Size Maximum

The Maximum member size property prevents the formation of thick features in the optimized shape.
It is supported for density-based optimization, level-set based optimization, mixable density, and
Shape Optimization.

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Structural Optimization Theory

Industry Motivation
This specification is motivated by several industrial manufacturing processes. Examples include:

• During casting processes, a maximum member size is directly related to the cooling process
of the parts where the distance to shape boundaries determines solidification times. Larger
members require a more elaborate solidification system to remove the shrinkage porosity
outside of the cast part and therefore increase manufacturing costs.

• During additive manufacturing processes, you can avoid large members that result from the
distortion created during the solidification of each layer by thermal residual stress.

Member Size Maximum Definition

Theoretically, the computation of the maximum member size is performed in two steps:

1. The application computes the pointwise distance by selecting a point inside of the shape
that it then extends to the boundary. [13 (p. 349)], [14 (p. 349)].

2. The maximum value of the distance field is defined as the maximum thickness of the structure.

Furthermore, the above formulation presents two critical drawbacks:

• It is not derivable due to the Maximum operator and therefore is not suitable for gradient-
based optimization algorithms.

• As illustrated below, it is not permissive because it tracks violation regions that should be ig-
nored [13 (p. 349)].

However, the devised formulation is appropriately adjusted to overcome these two problems. As a
result, the limit value might be violated in some limited regions of the optimized shape.

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 Manufacturing Constraint Background

Distortions close to joints of structural members to respect the maximum member size limit (dmax) in a pointwise m
(left): dmax is not respected close to joints; (right): dmax is respected everywhere.

For the Mixable Density and Level Set based methods, the Member Size constraint includes the
Measurement Type property. It provides the following options:

• Isotropic: For this setting, the formulation of member size is not directional. The constraint is
satisfied when you preserve the distance in any direction. For example, for the plate illustrated
below, the maximum thickness corresponds to its height.

• In-Plane: For this setting, the formulation of member size approximates the thickness in the
selected plane. To enable this capability, when you select this option, a Coordinate System
and a Plane property display. You specify a desired coordinate system that you use to define
a desired plane. Using the plate illustrated below again, Plane property options specify:

– YZ Plane: Maximum thickness approximates its height.

– XY Plane: Maximum thickness approximates its width.

– XZ Plane: Maximum thickness approximates its height.

The In-Plane definition of the thickness is of particular interest when designing the ribs in
cast parts, where you select the thickness plane perpendicular to the pull-out direction.

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Structural Optimization Theory

Setup and Technical Specifications

The setup requires you to specify the upper limit so that it does not exceed, denoted dmax, in terms
of length. However, for the sake of accuracy in the calculation of the member size, dmax must respect
a certain ratio with respect to dxAVG, as shown in the following table.

Additionally, for the Mixable Density and Level Set based methods, you can change the settings of
the Measurement Type property to account for isotropic planar formulations of the thickness.

Density Based Mixable Density Level Set Based Shape

Optimization

Ex- Using the options, Exclusion regions are inherently considered in the member
clu- Include Exclusions size evaluation.
sion or Exclude
Re- Exclusions, of the In case the thickness of the exclusion region exceeds ,
gion Region of the constraint cannot be respected during the optimization
Manufacturing and therefore, is automatically re-adjusted to comply
Constraint and/or with the exclusion region.
Region of Min
Member Size
properties of the
Analysis Settings
object, you can
specify whether to
include or exclude
exclusions.
Re- The member size is computed with respect to NA NA
tained the 0.5 iso-contour of the density field.
Threshold
Modifying the Retained Threshold property
changes the member size of the shape.
Meas- NA The property’s options, Isotropic and In- NA
ure- Plane, enable you to further define the
ment thickness for your application. The In-
Type Plane option also enables you to
approximate the thickness over a specified

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 Manufacturing Constraint Background

Density Based Mixable Density Level Set Based Shape

Optimization
plane as defined using the Coordinate
System and Plane properties.

Recommendations
Note the following:

• The Maximum Member Size constraint tends to deliver more complex designs.

• Ansys recommends that you use a fine mesh if you expect additional details in the geometry.

• As with any constraint, the Maximum Member Size affects the objective performance. Specific-
ally, if you reduce , the feasible domain shrinks and likely leads to a smaller objective
gain.

• When you set the Measurement Type property to In-Plane, thin regions with large in-plane
thickness may still appear. This is a limitation inherent to the approximation method.

Examples
Pillar Structure

For the following example, the Optimization Type property is set to the Topology Optimization
– Level Set Based option. This analysis uses a pillar structure clamped on the bottom with a
vertical load applied to the top, as illustrated below. The optimization problem is to minimize the
structural compliance under a volume fraction constraint of 0.4.

Example File

Download the following project file to examine the feature in more detail:

Project File (Member_Size_Max_Pillar_Structure.wbpz):

Set Up and Mesh

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Structural Optimization Theory

Here is the finite element mesh (144,828 elements).

No Maximum Member Size

The following Topology Density result and User Defined Result, show the optimized result
without considering any maximum member size constraints. As expected, the optimized shape
is a cylinder. Note that the User Defined Result shown below is a cutout of the result using the
Section Plane feature.

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 Manufacturing Constraint Background

Including Maximum Member Size

Adding an maximum member size constraint of 0.02 leads to the optimized shape shown below.
One can observe the indentations that are created to satisfy the maximum member size constraint.
The expected impact of the maximum member size constraint is clearly seen, reducing the max-
imum distance from the points inside the shape to the structural boundary.

Engine Bracket

For the following example, the Optimization Type property is set to the Topology Optimization
– Level Set Based option. The optimization problem consists of:

• Minimizing the structural compliance under a volume fraction constraint of 0.4.

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Structural Optimization Theory

• A Maximum Member Size constraint with dmax = 1.0e-02.

• A Pull-Out Direction constraint in the Z-direction.

• A Cyclic Repetition Design Constraint with 4 sectors enforced.

Example File

Download the following project file to examine the feature in more detail:

Project File (Member_Size_Max_Engine_Bracket.wbpz):

Mechanical Setup

The upstream Static Structural system is specified with two displacements, a force, and a moment,
as illustrated.

Here is the finite element mesh (153,729 elements).

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 Manufacturing Constraint Background

The following Topology Density result shows the optimized result without considering an max-
imum member size constraint.

And here you can see the optimized shape and cross-sectional density for dmax of 0.01.

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Structural Optimization Theory

Plate Reinforcement

For the following example, the Optimization Type property is set to the Topology Optimization
– Level Set Based option. This analysis examines the design of a reinforcement structure above
a plate structure. The optimization problem consists of:

• Minimizing the structural compliance under a volume fraction constraint of 0.4.

• A Maximum Member Size constraint with dmax = 6mm.

• A Pull-Out Direction constraint in the Y-direction.

• A double Symmetry constraint in the XY and YZ planes.

Mechanical Setup

As illustrated, the upstream Static Structural system is specified with a Fixed Support (A), one
Displacement (B), and a Force (C) applied at the center of the bottom side of the body.

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 Manufacturing Constraint Background

Here is the finite element mesh (643,900 elements) and the Exclusion Region.

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Structural Optimization Theory

The following Topology Density result shows the optimized result without considering a maximum
member size constraint.

Here is a result of the optimized shape for dmax = 6mm with the Measurement Type property
set to Isotropic.

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 Manufacturing Constraint Background

Here you can see the optimized shape for dmax = 6mm with the Measurement Type property
set to In-Plane, the Coordinate System property set to Global Coordinate System, and the
Plane property set to XZ Plane.

For this example, you can verify how using the In-Plane setting for the Measurement Type
property for a Maximum Member Size constraint, together with the Pull-Out Direction constraint,
can produce a rib-type structure.

References (p. 349)

[13] G. Allaire, F. Jouve, G. Michailidis, Thickness control in structural optimization via a level set
method, Structural and Multidisciplinary Optimization, 2016.

[14] Fernandez, E., Yang, K.K., Koppen, S., Alarcon, P., Bauduin, S., Duysinx, P., Imposing minimum and
maximum member size, minimum cavity size, and minimum separation distance between solid
members in topology optimization. Computer Methods in Applied Mechanics and Engineering, 2020.

4.1.3. Member Size Gap Size

The Gap Size constraint prevents the formation of closely spaced features in the optimized shape.
The appearance of such features is more pronounced when the maximum member size constraint is
used, since the algorithm may satisfy the maximum member size constraint by placing small holes
to reduce the size of large features. It is only available for the level-set based optimization method
and can only be activated in conjunction with the Maximum member size property.

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Structural Optimization Theory

Industry Motivation
This specification is motivated by several industrial manufacturing processes:

1. During casting process, it is linked to the capability of constructing molds with thin features
as well as with their life cycle.

2. During milling process, as well as other tooling processes, it is related to the characteristics
of the tooling machine (head and bit radius, etc.).

Gap Size Definition

Theoretically, the computation of the gap size is performed in three steps:

1. The pointwise distance between structural members is computed for every point on the
boundary along the exterior normal vector.

2. The minimum value of the distance field is defined as the gap size of the structure.

3. The gap size inherits the same Measurement Type property specification as the Maximum
Member Size constraint to which it is related.

However, this formulation presents two main drawbacks:

• It is not derivable, due to the minimum operator and the computational procedure, therefore,
it is not suitable for gradient-based optimization algorithms.

• It is quite restrictive for topology optimization since it hinders structural members from ap-
proaching each other and finally merging.

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 Manufacturing Constraint Background

A specific formulation has been devised to overcome these problems. As a consequence of adopting
a rather qualitative formulation [14 (p. 349)], closely spaced features may still appear in the optimized
shape.

Setup and Technical Specifications

The setup only requires specifying the lower limit not to violate, denoted , in terms of length
units. However, for the sake of accuracy in the calculation of the member size, , must respect
a certain ratio with respect to , as shown below.

Level Set Based

Both relations are motivated for accuracy reasons. However:

• The lower limit relation is required, that is, is automatically

rounded-up to 0.40dmax if the limit ratio is not respected.

• The upper limit relation is rather a recommendation.

Recommendations
As any constraint, the Gap Size affects the objective performance. Namely, by increasing , the
feasible domain shrinks and probably leads to smaller objective gain.

Examples
Pillar Structure

For the following example, the Optimization Type property is set to the Topology Optimization
– Level Set Based option. This analysis uses a pillar structure clamped on the bottom with a
vertical load applied to the top, as illustrated below. The optimization problem is to minimize the
structural compliance under a volume fraction constraint of 0.4.

Example File

Download the following project file to examine the feature in more detail:

Project File (Member_Size_Gap_Size_Pillar.wbpz):

Set Up and Mesh

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Structural Optimization Theory

Here is the finite element mesh (144,828 elements).

No Member Size Constraint

As shown from the Topology Density result as well as a User Defined Result, the optimized
result without considering manufacturing constraints. As expected, the optimized shape is a cyl-
inder. Note that the User Defined Result shown below is a cutout of the result using the Section
Plane feature.

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 Manufacturing Constraint Background

Including Member Size Constraint

Adding an maximum member size constraint of 0.012 leads to the optimized shape shown below.
One can observe the indentations that are created to satisfy the maximum member size constraint.
The structural compliance is equal to 1.85953 e-04 (+1.5%).

Including Gap Size Constraint

Adding a Gap Size constraint with limit dGapSize = 0.012 results in the optimized shape shown
below, wherein the distance between structural members increases. The structural compliance
equals to 1.92452 e-04, namely 5% less stiff due to the maximum member size and gap size
constraints.

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Structural Optimization Theory

Plate Reinforcement

For the following example, the Optimization Type property is set to the Topology Optimization
– Level Set Based option. This analysis examines the design of a reinforcement structure above
a plate structure. The optimization problem consists of:

• Minimizing the structural compliance under a volume fraction constraint of 0.4.

• A Pull-Out Direction constraint in the Y-direction.

• An In-Plane Maximum Member Size constraint with dmax = 6mm, perpendicular to the
Pull-Out Direction (XZ Plane).

• A Gap Size constraint with dGapSize = 6mm.

• A double Symmetry constraint in the XY and YZ planes.

Example File

Download the following project file to examine the feature in more detail:

Project File (Member_Size_Gap_Size_Plate.wbpz):

Mechanical Setup

As illustrated, the upstream Static Structural system is specified with a Fixed Support (A), one
Displacement (B), and a Force (C) applied at the center of the bottom side of the body.

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 Manufacturing Constraint Background

Here is the finite element mesh (81,675 elements).

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Structural Optimization Theory

No Member Size Constraint

The following Topology Density result shows the optimized result without considering a member
size constraint.

Specify Isotropic Measurement Type

Here is a result of the optimized shape with the Measurement Type property set to Isotropic.

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 Manufacturing Constraint Background

Specify In-Plane Measurement Type

Here you can see the optimized shape for the Measurement Type property set to In-Plane and
the Plane property set to XY Plane for the illustrated coordinate system.

Members that are thick on this plane are split into smaller members. This creates a design that
is difficult to manufacture.

Including Gap Size Constraint

Adding a Gap Size constraint produces a better separation of structural members, contributing
to the overall manufacturability of the design.

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Structural Optimization Theory

4.1.4. Pull Out Direction

The Manufacturing Constraint (p. 72) Pull Out Direction enables you to deliver a design that is
compatible with the casting process by preventing the formation of undercuts and internal holes
[13 (p. 349)].

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 Manufacturing Constraint Background

This constraint also provides the following Pull Out Options:

• No-Hole: This option aims to simplify the casting process. It ensures that the shape does not
perforate along the specified direction and enables it to shrink perpendicular to the pull-out
direction.

• Stamping: You use this option to create a design that is compatible with a stamping or forging
process. This option makes sure the shape does not perforate along the specified pull-out
direction.

Go to a section topic:

• Supported Methods (p. 205)

• Setup and Technical Details (p. 206)

• Recommendations and Observations (p. 208)

• Examples (p. 209)

• References (p. 237)

Supported Methods
The Pull Out Direction constraint is available for the Mixable Density, Level Set, and Density Based
optimization methods. These methods employ a built-in approach. In a built-in approach, this constraint
is embedded directly into the mathematical formulation of the optimization problem. It is treated
and satisfied for each iteration. Note that only the Level Set method provides the Pull Out Options
properties.

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Structural Optimization Theory

Setup and Technical Details

• The basic setup requires you to specify the Axis and the Direction properties along which the Pull
Out Direction constraint is enforced.

• For the Level Set Based method, additional options are available, as described below.

Method
Property Mixable Density/Density Based Description
Stamping NA Imposes n
pull-out d
No-Hole NA Imposes n
direction.
to the pul

Note: The
Axis The Axis property enables you to specify the axis of the Coordinate Sy
Direction The Direction property enables you to specify whether the shape boun
(two-sided) directions.
Parting Surface Control For the Density Based method, when you set the Dir- For the Le
ection property to Both Directions, the application Both Dire
automatically imposes a parting surface. This surface to impose
passes from the origin of the coordinate system and Group ca
is perpendicular to the axis you specify in the Axis and a plan
property.
Exclusion Region You can decide whether to Include or Exclude Exclusion
Exclusions from the Analysis Settings. automatic
images be

Here is an example of the extension of the Exclusion Region in a Level Set Based Optimization using
the Pull Out Direction constraint.

Exclusion Surfaces (a)

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 Manufacturing Constraint Background

Exclusion Region (b) without Pull Out constraint. Extended Exclusion Region for (c) one-sided pull
out in the +Z direction.

One-sided pull out (d) in the -Z direction and (e) two-sided pull out along the Z-axis.

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Structural Optimization Theory

Recommendations and Observations

• As with any constraint, the Pull Out Direction shrinks the feasible domain and leads to smaller
objective gain.

• With the No-Hole constraint, tiny perforations may still appear in the optimized shape (see the il-
lustrations section).

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 Manufacturing Constraint Background

Examples

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Structural Optimization Theory

Pull Out Example

This analysis examines the effect of the Pull Out Direction Manufacturing Constraint on a can-
tilever model with a spiral shape. The optimization problem is to minimize the structural com-
pliance under a volume fraction constraint of 0.4.

Example File

Download the following project file to examine the feature in more detail:

Project File (PullOutExample_SpiralCantilever.wbpz):

Set Up and Mesh

The environmental conditions and mesh are illustrated here.

No Manufacturing Constraints

This result shows the optimized shape with no manufacturing constraints. The shape presents
some cavities and undercuts along the Y-direction (indicated with red arrows). For this result,
the structural compliance equals 5.22538e-02.

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 Manufacturing Constraint Background

Pull Out Direction in Both Directions

Here is the optimized shape with the Axis property set to Y Axis and the Direction property
set to Both Directions. Using a two-sided Pull Out Direction constraint along the Y axis
results, the previous cavities and undercuts have disappeared. The value of the structural
compliance increased slightly to 5.27043e-02 (+0,9%).

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Structural Optimization Theory

One-Sided Pull Out Direction

As illustrated below, changing the optimized shape by setting the Axis property set to Y
Axis and the Direction property set to Along Axis, the shape changes dramatically because
the side oriented in the -Y direction is considered as a parting surface. Disposing less freedom
to evolve than in the two-sided, the value of the structural compliance increases more than
previously, to 5.85545e-02 (+12.1%).

Pull Out Direction and Member Size Constraints

The above formulation includes some thick regions that may present a problem to manufac-
ture. Here you add a Member Size constraint specified with the Maximum property set to
Manual and the Max Size property set to 4mm (dmax = 4.0e-03). Adding the constraint helps
to redistribute the available material, while respecting the Pull Out Direction constraint.
The Max Size property specification (dmax = 4.0e-03) substitutes thick regions with thin
nerves. By chance, this solution is better than the initial nominal optimization.

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 Manufacturing Constraint Background

Pull Out with Parting Surface

Using the Level Set Based optimization method, this analysis examines the effect of the Pull
Out Direction Manufacturing Constraint on a suspending arm, under different options for the
parting surface definition. The optimization problem is to minimize the structural compliance
under a volume fraction constraint of 0.4 and a two-sided Pull Out direction constraint.

Example File

Download the following project file to examine the feature in more detail:

Project File (PullOutWithPartingSurface_SuspendingArm.wbpz):

Set Up and Mesh

The mesh and environmental conditions are illustrated here. The finite element model
contains 67,888 elements.

A Fixed Support (B) is scoped to the inner surface of the three parts on the left side of the
model and an inclined Force (A) is applied to the inner surface of the part on the right side.

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Structural Optimization Theory

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 Manufacturing Constraint Background

Pull Out Direction without Parting Surface

Here is the optimized shape with the Axis property set to Z Axis and the Direction property
set to Both Directions. The Parting Surface Control property is set to Free. For this result,
the structural compliance equals 0.00270791.

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Structural Optimization Theory

Pull Out Direction with Parting Surface

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 Manufacturing Constraint Background

Define the Parting Surface properties:

• Parting Surface Control property is set to Force Plane.

• Parting Surface Coordinate System is defined using a user-defined coordinate

system, at the at the center of mass/gravity of the optimized region.

• Parting Surface Plane property is set to set to XY Plane.

Here is the optimized shape. The compliance increases to 0.00282641 (+4,4%).

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Structural Optimization Theory

Stamping Example

Using the Level Set Based optimization method, this analysis examines the effect of the Pull
Out Direction Manufacturing Constraint on an engine bracket part. The optimization problem
is to minimize the structural compliance under a volume fraction constraint of 0.2.

Example File

Download the following project file to examine the feature in more detail:

Project File (Pull_Out_Stamping_EngineBracket.wbpz):

Set Up and Mesh

The mesh and environmental conditions are illustrated here. The finite element model
contains 153,729 elements.

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 Manufacturing Constraint Background

Displacements (A and B) are scoped to two faces at the left hand corner of the base. A Mo-
ment and Force (C and D) are specified on the inner surface of the bracket.

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Structural Optimization Theory

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 Manufacturing Constraint Background

No Manufacturing Constraints

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Structural Optimization Theory

The optimized result without considering manufacturing constraints is illustrated below.

The structural compliance equals 0.0159048.

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 Manufacturing Constraint Background

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Structural Optimization Theory

Pull Out Constraint

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 Manufacturing Constraint Background

Here, the Pull Out Option property is set to Stamping and specified in the Z-direction. This
produces an optimized shape where no perforation appears in the Z-direction. The value of
the structural compliance increases to 0.0176963 (+11.3%).

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Structural Optimization Theory

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 Manufacturing Constraint Background

No Hole Example

Using the Level Set Based optimization method, this analysis examines the effect of the Pull
Out Direction Manufacturing Constraint on a suspending arm. The optimization problem is to
minimize the structural compliance under a volume fraction constraint of 0.4 and a two-sided
Pull Out Direction constraint in the Y-axis.

Example File

Download the following project file to examine the feature in more detail:

Project File (Pull_Out_NoHole_SuspendingArm.wbpz):

Set Up and Mesh

The mesh and environmental conditions are illustrated here. The finite element model
contains 14,714 elements.

A Fixed Support (B) is scoped to the inner surface of the three parts on the right side of the
model and a vertical Force (A) is applied to the inner surface of the part on the right side.

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Structural Optimization Theory

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 Manufacturing Constraint Background

Pull Out Constraint

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Structural Optimization Theory

For this result, the Pull Out Option property is set to None. The optimized shape for the
constraint pulled out in both directions (Direction property set to Both Directions) along
the Y-axis (Axis property set to Y Axis). The structural compliance equals 1.34666e-03.

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 Manufacturing Constraint Background

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Structural Optimization Theory

Pull Out Constraint Stamping

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 Manufacturing Constraint Background

For this result, the Pull Out Option property is set to Stamping. The optimized shape for
the constraint pulled out in both directions (Direction property set to Both Directions)
along the Y-axis (Axis property set to Y Axis). There are now no perforations along the Y-
axis. The structural compliance increases to 1.3527e-03 (+0.45%).

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Structural Optimization Theory

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 Manufacturing Constraint Background

Pull Out Constraint No Hole

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Structural Optimization Theory

For this result, the Pull Out Option property is set to No Hole. The optimized shape for the
constraint pulled out in both directions (Direction property set to Both Directions) along
the Y-axis (Axis property set to Y Axis). Compared to the default option, the small hole
close to the loading disappears. More freedom to shrink perpendicular to the Y-axis is
provided compared to the Stamping option. The structural compliance is similar to the
result shown above (+0.1%).

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 Manufacturing Constraint Background

References
[13 (p. 349)] G. Allaire, F. Jouve, G. Michailidis, Molding direction constraints in structural optimization
via a level-set method, Variational Analysis and Aerospace Engineering: Mathematical Challenges for
the Aerospace of the Future, 2016.

4.1.5. Millability
The Millability Manufacturing Constraint ensures that your optimized design is compatible with a
four-axis milling process by restricting geometry that cannot be accessed or machined using the
available tool movements. This manufacturing constraint is only available for Topology Optimization
- Level Set Based method. This method uses a built-in approach. In a built-in approach, this constraint
is embedded directly into the mathematical formulation of the optimization problem. It is treated
and satisfied for each iteration.

Go to a section topic:

• Overview (p. 238)

• Setup and Technical Details (p. 238)

• Recommendations and Observations (p. 238)

• Millability Example (p. 239)

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Structural Optimization Theory

Overview
Here is an illustration of a four-axis milling machine, showing all four axes.

Setup and Technical Details

This manufacturing constraint requires you to specify the following properties. These properties are
included in the Location and Orientation category of the Details pane.

Property Description
Co- Specify a coordinate system for the model.
ordin-
ate
Sys-
tem
Ax- Specify the axis around which the rotation occurs. Options include X Axis (default), Y
is Axis, and Z Axis. Based on your selection, the application automatically divides the
Optimization Region into regions and assigns a specific milling direction to each region.
These milling directions are oriented perpendicular to the selected axis.

Recommendations and Observations

• As with any constraint, applying the Millability constraint reduces the feasible design space and
may result in a smaller improvement in the objective function.

• The current methodology does not account for specific tooling parameters.

• The automated assignment of milling directions to each region by the application is a limitation
of the current approach and may lead to sub-optimal designs.

• You may notice non-smooth transitions in the optimized geometry, particularly at the junctions
between regions with different milling directions. These are numerical artifacts caused by the im-
plicit decomposition of the optimization region and do not affect the overall quality or performance
of the final shape.

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 Manufacturing Constraint Background

Millability Example
This example examines designs created with and without the Millability Manufacturing Constraint
on an engine bracket model. The goal of the optimization example is to reduce structural compliance
while maintaining a volume fraction constraint of 0.4. The example tests different milling directions
to achieve the best performance.

Set Up and Mesh

The finite element model includes 1,225,182 elements.

Fixed Supports (A) are scoped to the cylinders as illustrated and a Force (B) is applied to the
center cylinder.

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Structural Optimization Theory

No Millability Constraint

The following Topology Density results shows the optimization without considering a Millability
constraint. The structural compliance equals 1.29497e-07.

Millability Constraint X Axis

The following shows the result of a Millability constraint specified on the X-Axis. As noted above,
the shape is split into four regions and each region has a predefined milling direction (+Y, -Y, +Z,
-Z). As highlighted, the result shows some rough regions at the junctions between these regions.
The structural compliance increased by +2.8%.

Millability Constraint Y and Z Axis

The following results illustrate a Millability constraint specified in the Y-Axis and in the Z-Axis.
The optimization demonstrates significantly lower performance efficiency compared to the previous

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 Manufacturing Constraint Background

configuration (X Axis). This is reflected in the objective function, which increases by 52.9% along
the Y Axis and 46.0% along the Z Axis relative to the unconstrained result.

Millability on the Y-Axis

Millability on the Z-Axis

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Structural Optimization Theory

4.1.6. Extrusion
The Extrusion constraint enables you to makes sure that the resulting cross-section of the final design
is kept constant all along the selected axis. This constraint is supported for the following optimization
methods:

• Topology Optimization - Mixable Density

• Topology Optimization - Density Based

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 Manufacturing Constraint Background

• Shape Optimization

Important:

The application only supports the specification of one Extrusion constraint for each
Structural Optimization analysis.

Industry Motivation
Principally, the constant cross-section requirement stems from extrusion-based manufacturing processes
(hot extrusion, cold extrusion, etc.). However, it can also be used to facilitate the manufacturing process
in different frameworks, such as to enforce constant profile of features in casting.

Setup and Technical Specifications

This constraint requires you to specify the following properties. These properties are included in the
Location and Orientation category of the Details pane.

Property Description
Co- Specify the desired Cartesian or Cylindrical coordinate system for the extrusion.
ordin-
ate
Sys-
tem
Ax- Specify the axis of the extrusion. Options include X Axis, Y Axis, and Z Axis.
is
Note:

Only the Z-Axis option is supported when you specify a Cylindrical

coordinate system.

Recommendations
Like all constraints, the Extrusion constraint may shrink the feasible domain and lead to smaller ob-
jective gain. Plan your design accordingly.

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Structural Optimization Theory

Examples

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 Manufacturing Constraint Background

Cantilever Beam Example

The following example uses a typical cantilever beam using the Topology Optimization -
Mixable Density method. The optimization problem consists in minimizing the structural
compliance under a volume fraction constraint of 0.4.

Example File

Download the following project file to examine the feature in more detail:

Project File (Extrusion_CantileverBeam.wbpz):

Set Up and Mesh

The mesh and environmental conditions are illustrated below. The finite element model
contains 31,755 elements.

A Fixed Support (A) is applied on the left side surface of the domain and a vertical Force
(B) is applied in the middle of the surface on the right side.

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Structural Optimization Theory

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 Manufacturing Constraint Background

Optimization Without the Extrusion Constraint

Here is the result without considering design constraints. The structural compliance equals
2.05523e-02.

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Structural Optimization Theory

Optimization Using Extrusion Constraint

Adding an Extrusion constraint along the Z-axis, to obtain a uniform cross-section, results
in the optimized shape shown below. This shape resembles a typical IPE-type beam. As ex-
pected, the structural compliance increases to 2.41985e-02 (+17.7%).

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 Manufacturing Constraint Background

Engine Bracket Example

Using the Shape Optimization method, the following example examines an engine bracket
model. The optimization problem consists in minimizing the mass under a constraint on the
maximum displacement along the Z-direction over the region where the load is applied. In ad-
dition, an Extrusion constraint along the Y-axis is added to maintain a uniform cross-section of
the central part.

Example File

Download the following project file to examine the feature in more detail:

Project File (Extrusion_EngineBracket.wbpz):

Set Up and Mesh

The mechanical setup and mesh is shown below. The finite element model is comprised of
241,036 elements.

The bracket is clamped with Fixed Supports (A) and a vertical Force (B) is applied on a
region on the right.

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Structural Optimization Theory

Here, a Primary Criterion specifies a constraint on the maximum displacement along the
Z-direction over the region where the load is applied.

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 Manufacturing Constraint Background

Optimization Region

The Optimization Region setup is illustrated below. Only the central body of the bracket
(in blue) is optimized while the regions around the boundary conditions (in red) are kept
fixed during the optimization process.

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Structural Optimization Theory

Optimized Shape

Here is the optimized shape with the Extrusion constraint along the Y-axis. The shape is
modified in the X-Z plane and the profile remains constant along the Y-axis. The total mass
reduces by 9,4%.

4.1.7. AM Overhang Constraint

Overhang features, or simply "overhangs," are unsupported solid features that rise in the build direction
when using Additive Manufacturing (AM) processes. They are mainly related to the printing angle,
but other factors, such as feature length, may also be included.

Available for the Mixable Density, Density Based, and Level Set Based optimization methods, the
AM Overhang Constraint (p. 72) manufacturing constraint aims to create self-supporting designs that
prevent the formation of these overhanging regions.

Go to a section topic:

• Overview (p. 253)

• Setup and Technical Details (p. 254)

• Recommendations and Observations (p. 255)

• Example (p. 255)

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 Manufacturing Constraint Background

Overview
For any AM process, support structures can lead to excessive printing time and cost [15 (p. 349)]. More
precisely, for metal powder bed fusion processes, overhang features can significantly impact the
structural quality of the printed part. For fused deposition modeling (FDM) processes, the existence
of supports may significantly deteriorate the quality of the outer surface, having a strong visual impact
on the printed part, as illustrated below.

Figure 4.1: Printing Angle Impact on Quality of Surface in FDM [15 (p. 349)].

In theory, the computation of the overhang angle constraint is performed in two steps:

1. The inner product between the exterior normal vector and the build direction is computed
for every point of the structural boundary.

2. The minimum value of shall be greater than the threshold provided by the angle
. That is:

However, the above formulation presents two drawbacks:

• It is not derivable due to the minimum operator and therefore not suitable for gradient-based
optimization algorithms.

• It is not applicable for all methods, mainly because it requires geometric information that is
not directly available for the density-based methods.

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Structural Optimization Theory

The devised formulation depends on the Structural Optimization framework described in the following
table.

Table 4.1: AM Overhang Constraint Formulation

Mixable Density /Density Based Methods Level Set Based Method

The built-in approach is based on filtering The theoretical definition is adopted and is appropriately
techniques [16 (p. 349)]. adjusted to overcome the differentiability issue [15 (p. 349)].

Figure 4.2: Overhanging Region (red) for Shape Ω Printed in Direction .

Setup and Technical Details

The setup requires specifying a Build Direction ( ) and the Overhang Angle ( ).

Table 4.2: Setup Parameters and Technical Details

Mixable/Density Based Method Level Set Based Method

27° 60°.

The overhang angle consists of the minimum allowed angle between the shape's
boundary and the print bed.
Exclusion You can decide whether to Include or Exclusion regions are inherently
Region Exclude Exclusions from the Analysis considered in the overhangs evaluation.
Settings.
Working All boundaries of the working domain
Domain that are not self-supported are
considered as print beds. Namely, they
are ignored by the constraint.

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 Manufacturing Constraint Background

Recommendations and Observations

• For the Level Set Based optimization method, the angle limit may still be violated along sharp
lines, where the normal vector is not accurately defined (see illustration for Y axis overhang (p. 257))
[16 (p. 349)]. Such shapes require linear supports during the printing process, that is, supports along
some two dimensional curve of the print bed.

• As with any constraint, the AM Overhang Constraint affects the objective performance. Namely,
by increasing the allowed overhang angle ( ), the feasible domain shrinks and likely results
in smaller objective gain.

Example
This example examines the effect of an AM Overhang Constraint Manufacturing Constraint on an
engine bracket model.

Example File

Download the following project file to examine the feature in more detail:

Project File (AM_Overhang_Constraint_Engine_Bracket.wbpz):

Set Up and Mesh

The specified mesh and the setup of the environment, shown in wireframe mode so that you can
clearly see the specified boundary conditions, are illustrated below. The optimization problem is
to minimize the structural compliance under a volume fraction constraint of 0.4.

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Structural Optimization Theory

No AM Overhang Constraint

Here are illustrations of the optimized result without considering an AM Overhang Constraint.
The structural compliance equals 1.29836e-07.

AM Overhang Constraint Z Axis

In the following, an AM Overhang Constraint is added for a build direction in the positive Z axis
( ) and for varied overhang angles ( = 60°, 45°, and 30°). The structural compliance
is increased by +7.4%, +6.3%, and +5.7% respectively and, as expected, increasing the overhang-
angle results in less objective gain.

AM Overhang Constraint + Z 60°

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 Manufacturing Constraint Background

AM Overhang Constraint + Z 45°

AM Overhang Constraint + Z 30°

AM Overhang Constraint Y Axis

In the following, an AM Overhang Constraint is added for a build direction in the positive Y axis
( ) and for an overhang angle of = 45°. The structural compliance equals
1.32978e-07 (+2.4%). Overhanging regions are removed, and the shape appears to be self-sup-
porting. However, as shown, this is achieved by forming linear overhangs and using some mater-
ial as supports for the 3D printing. This indicates that the choice of build-direction is not appro-
priate.

4.1.8. Housing
Supported for the Mixable Density and Level Set Based optimization methods, the Housing constraint
enables you to create watertight designs that enclose a given set of faces.

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Structural Optimization Theory

Description and Industrial Motivation

This constraint is used for several industrial applications where the structural design must not exhibit
holes and perforations, such as designing a container to house a liquid region.

Setup and Technical Details

This constraint requires you to specify faces that will encapsulate a shape. The final shape must contain
at least one layer of material of thickness surrounding the selected surfaces.

Recommendations and Observations

Ansys recommends that you have at least two layers of elements above the selected surfaces.

As with any constraint, the Housing constraint affects the objective performance. Due to the imposed
geometric restriction, the feasible domain shrinks and probably results in smaller objective gain.

Example
This example examines a clutch housing. Using the Level Set Based Optimization Method, this
problem consists of minimizing the structural compliance under a volume fraction constraint of 0.5.
In addition, it is required that no perforations exists between the exterior and the surfaces shown
below in red.

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 Manufacturing Constraint Background

Example File

Download the following project file to examine the feature in more detail:

Project File (Housing_Clutch.wbpz):

Set Up and Mesh

The specified mesh and the setup of the environment, are illustrated below. The displacement is
fixed at six locations (blue) and a horizontal load is applied on the inner surface (red). The finite
element model includes 242, 979 elements.

No Housing Constraint Specified

No Housing constraint is specified for the following result. The existing perforations violate the
housing specification and the structural compliance equals 3.22359e-04.

Housing Constraint Specified

When you add a Housing constraint, the optimization problem results in the optimized shape
shown below. As expected, the surfaces are encapsulated by the structural design and the struc-
tural compliance slightly increases to 3.25889e-04 (+1.1%).

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Structural Optimization Theory

4.1.9. Complexity Index

The Complexity Index Manufacturing Constraint enables you to minimize the creation of overly
complex structures.

Supported Methods
The Complexity Index constraint is only available only for Level Set Based optimization method.

Industrial Motivation
This constraint helps you limit the geometric complexity of your designs which directly impacts the
cost of production. Furthermore, this constraint type enables you to produce more organic, bio-mi-
metic designs, which facilitate aesthetically pleasing designs in development areas such as architecture
and furniture manufacturing.

Setup and Technical Details

The setup for this constraint requires only the specification of a lower limit that cannot be violated,
denoted by CIlimit ≥ 1.0.

Note: Complexity index values are non-dimensional. In fact, the sphere is considered as a reference
design where the Complexity Index is equal to 1.0 - the lowest supported value.

Recommendations and Observations

As with any constraint, the Complexity Index constraint affects the objective performance. Namely,
by reducing the CIlimit the feasible domain shrinks and leads to less complex designs with a likely
smaller objective gain.

Electrical Mast Example

This analysis optimizes a simplified electrical mast. The optimization problem consists in minimizing
the total volume under a compliance constraint of 0.13 Joule. A Cyclic Repetition Design Constraint
in the Z-direction with 4 sectors is also enforced.

Example File

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 Manufacturing Constraint Background

Download the following project file to examine the feature in more detail:

Project File (Complexity_Index_Electrical_Mast.wbpz):

Set Up and Mesh

The specified mesh and the setup of the environment are illustrated below. Fixed supports are applied
on the four faces highlighted in blue and force loads are applied on the upper portion of the model
(in red). This represents forces exercised by electrical cables.

The finite element model, illustrated below, is comprised of 251.988 elements.

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Structural Optimization Theory

Here are the results when no Complexity Index is specified and when an index of 3.5 is specified.

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 Manufacturing Constraint Background

Here, Complexity Index values of 2.5 and 2.0 are specified. As expected, the shape gets simplified
and the total volume increases by +17%, +42,3%, and +63% correspondingly.

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Structural Optimization Theory

4.2. Design Constraints Background

The Design Constraints (p. 83) available in the application enable you to impose specific design require-
ments that may derive from manufacturing processes, functional, and/or aesthetic criteria. For the fol-
lowing supported design constraints, this documentation provides some basic details of their numerical
implementation, limitations, and best-practices for efficient usage.

Go to a section topic:
4.2.1. Cyclic Repetition
4.2.2. Symmetry
4.2.3. Uniform
4.2.4. Pattern Repetition

4.2.1. Cyclic Repetition

The Cyclic Repetition constraint enables you to create a design that repeats around a specified axis,
for a required number of sectors, to produce a shape that is symmetric with respect to an axis of ro-
tation. This constraint is supported for the following optimization methods:

• Topology Optimization - Mixable Density

• Topology Optimization - Level Set Based

• Shape Optimization

• Topology Optimization - Density Based

Important:

The application only supports the specification of one Cyclic Repetition constraint for
each Structural Optimization analysis.

Industry Motivation
A cyclic-symmetric design is desirable because it is easy to manufacture and it is aesthetically appealing.

Setup and Technical Specifications

This constraint requires you to specify the following properties. These properties are included in the
Location and Orientation category of the Details pane.

Property Description
Number Specify the desired number of identical sectors to be used in your design.
of Sectors
Coordin- Specify the desired Cartesian or Cylindrical coordinate system. This coordinate
ate Sys- system determines the axis of cyclic symmetry.
tem

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 Design Constraints Background

Property Description
Axis Specify the axis of symmetry. Options include X Axis, Y Axis, and Z Axis.

Note:

Only the Z-Axis option is supported when you specify a

Cylindrical coordinate system.

Recommendations
Like all constraints, the Cyclic Repetition constraint may shrink the feasible domain and lead to
smaller objective gain. Plan your design accordingly.

Wheel Model Example

The following example is a simplified case of a wheel under deceleration forces. Using the Topology
Optimization - Level Set Based method, the goal of this optimization problem is to minimize the
structural compliance under a volume fraction constraint of 0.33. This problem utilizes a Pull Out
Direction constraint, specified in the X direction, and a Cyclic Repetition constraint to optimize the
shape.

Example File

Download the following project file to examine the feature in more detail:

Project File (Cyclic_Repetition_Wheel.wbpz):

Set Up and Mesh

The mesh and environmental conditions are illustrated below. The finite element model contains
64,384 elements.

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Structural Optimization Theory

A Fixed Support (A) is scoped to the center cylinder and two force loading conditions applied on a
specific portion of the surface (illustrated in red). One Force is defined as a tangential force (B) and
the other is a Force applied to the Normal of the surface (C).

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 Design Constraints Background

Here is a result of the optimized shape using Cyclic Repetition constrain specified with three (3)
sectors.

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Structural Optimization Theory

Here is a result of the optimized shape using Cyclic Repetition constrain specified with five (5) sectors.

4.2.2. Symmetry
The Symmetry constraint enables you to enforce a design that is symmetric with respect to a specified
plane. A symmetric design may be desirable both for manufacturing reasons (easy-to-produce) and
aesthetic appeal. This constraint is available for following optimization methods:

• Topology Optimization - Mixable Density

• Topology Optimization - Level Set Based

• Shape Optimization

• Topology Optimization - Density Based

Setup and Technical Specifications

You define the following properties of the Symmetry design constraint.

Note:

If you specify more than one Symmetry design constraint object, the symmetry planes
must be perpendicular to one another.

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 Design Constraints Background

Property Options/Description
Coordinate Sys- Select a desired Cartesian coordinate system from the drop-down menu for your
tem symmetry model.
Axis Use the property options, YZ Pane (default), XZ Plane, and XY Plane, to specify
the desired plane for the symmetry model.

Recommendations and Observations

There are cases, even when you expect your optimized shape to be symmetrical, that the resulting
optimized shape is not symmetrical. Use the Symmetry design constraint to ensure a perfect symmet-
rical design. However, like all constraints, the Symmetry constraint may shrink the feasible domain
and lead to smaller objective gain.

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Structural Optimization Theory

Example Problems

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 Design Constraints Background

Cantilever Beam Example

This example compares the results of an optimized model with and without a specified Symmetry
design constraint. The example model is a cantilever beam that includes a cylindrical hole
through the middle of the solid body in the Y-direction. The optimization problem consists of
minimizing the structural compliance, under a volume fraction constraint of 0.3 using the Topo-
logy Optimization - Level Set Based method.

Example File

Download the following project file to examine the feature in more detail:

Project File (Symmetry_Cantilever_Beam.wbpz):

Set Up and Mesh

The mesh and environmental conditions are illustrated below. The finite element model
contains 39,123 elements.

A Fixed Support (A) is scoped to the right side of the body and a Force (B) is applied to
the surface of the cylindrical hole in the Z direction.

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Structural Optimization Theory

The problem uses the cylindrical hole to create a Coordinate System originating at the
center of gravity of the cantilever beam.

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 Design Constraints Background

Optimization Without the Symmetry Constraint

Here is the optimized result without using the design constraint. Due to the symmetries of
the mechanical setup, the optimized shape is doubly symmetric with respect to the XY and
XZ planes of the coordinate system. The structural compliance equals 1.62567e-03.

Optimization Using Symmetry Constraint

Here is the optimized result using the design constraint specified in the YZ plane. The op-
timized shape is now symmetric with respect to all three planes (YZ, XZ, XY). The structural
compliance increases to 3.11336e-03 (+91.5%).

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Structural Optimization Theory

Exhaust Valve Example

The example model is an exhaust valve. Using the Shape Optimization method, this optimization
problem consists of minimizing the Equivalent (von-Mises) Stress, which exceeds the structural
steel yield value for the initial design, under the constraint that the total mass cannot increase.

Example File

Download the following project file to examine the feature in more detail:

Project File (Symmetry_Exhaust_Valve.wbpz):

Setup and Mesh

The mesh and environmental conditions are illustrated below. The finite element model
contains 241,171 elements.

A Fixed Support (A) is scoped to the face illustrated below in purple, three Displacements
(B/C/D) are specified on the yellow faces, and a Pressure (E) is applied to the interior of the
body, as highlighted in red.

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 Design Constraints Background

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Structural Optimization Theory

Static Structural Result

Here is the Equivalent Stress result for the upstream Static Structural analysis.

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 Design Constraints Background

Optimization Not Using Symmetry Constraint

Here you can see the optimized shape without design constraints and the total movement
of surface nodes. Because the field is not symmetric with respect to the XY-plane, the initial
symmetry is lost. The Equivalent (von-Mises) Stress reduces from 277.9MPa to 181.4 MPa
(-34,7%).

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Structural Optimization Theory

Optimization Using Symmetry Constraint

Here is the optimized shape with a Symmetry constraint specified in the XY-plane. The initial
symmetry is preserved as shown by the symmetrical total movement of the nodes. The
Equivalent (von-Mises) Stress result reaches a slightly higher value of 183.9 MPa (-33,8%).

4.2.3. Uniform
The Uniform constraint enables you to enforce a design that has a constant Topology Density on all
layers parallel to a user-defined plane. This constraint is only supported for the Topology Optimization
- Density Based method.

Important:

The application only supports the specification of one Uniform constraint for each Struc-
tural Optimization analysis.

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 Design Constraints Background

Industry Motivation
The principal motivation for this constraint derives from searching for the optimal ligaments between
structural bodies, while avoiding the use of discrete variables.

Setup and Technical Specifications

This constraint requires you to specify the following properties. These properties are included in the
Location and Orientation category of the Details pane.

Property Description
Coordinate Specify the desired Cartesian coordinate system for the uniform model.
System
Axis Specify the desired plane. Options include XY Plane, XZ Plane, and YZ Plane.

Recommendations
Like all constraints, the Uniform constraint may shrink the feasible domain and lead to smaller objective
gain. Plan your design accordingly.

Example
This example compares the results of an optimized model with and without a specified Uniform
design constraint. The example model is a two-dimensional simplified case of a bracing system for
the facade of high-rise buildings. The optimization problem consists in minimizing the structural
compliance under a volume fraction constraint of 0.2 using the Topology Optimization – Density
Based method. In addition, a Pattern Repetition (p. 284) constraint is imposed, such that the design
repeats at every floor.

Example File

Download the following project file to examine the feature in more detail:

Project File (Uniform_Bracing_System.wbpz):

Set Up and Mesh

The mesh and environmental conditions are illustrated below. The finite element model contains
1486 elements.

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Structural Optimization Theory

A Fixed Support (A) is defined on the bottom edge of the domain and a horizontal Force (B) is applied
on the edge of the left side of the surface. This force mimics wind loads.

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 Design Constraints Background

The optimization setup is shown below. Only the central part of the domain is optimizable and it
represents the bracing system.

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Structural Optimization Theory

Here is the optimized result without a Uniform constraint. The structural compliance equals 23.8428.

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 Design Constraints Background

Here is the result with a Uniform constraint in the XY Plane. The design of the bracing system is
simplied using straight bars of uniform length. As expected, the structural compliance increases to
53.2848 (+123.5%).

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Structural Optimization Theory

4.2.4. Pattern Repetition

The Pattern Repetition constraint enables you to enforce a design that has a repetitive pattern along
the specified axis. The number of repetitions is specified using an offset value. This constraint is
available for following optimization methods:

• Topology Optimization - Mixable Density

• Topology Optimization - Level Set Based

• Lattice Optimization

• Topology Optimization - Density Based

Industry Motivation
From a manufacturing perspective, repetition helps to significantly reduce the production costs in
most manufacturing processes. Moreover, from an aesthetic perspective, repetitive designs are fre-
quently required in architecture.

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 Design Constraints Background

Setup and Technical Specifications

This constraint requires you to specify the following properties. These properties are included in the
Location and Orientation category of the Details pane.

Property Description
Coordinate Specify the desired Cartesian coordinate system for the repetitive pattern.
System
Axis Specify the desired axis of repetition. Options include X Axis, Y Axis, and Z
Axis.
Offset Specify the desired distance between repetitions.

Important:

In order to use multiple Pattern Repetition constraint in your analysis, the axis planes of
each constraint must be perpendicular to one another.

Recommendations
Like all constraints, the Pattern Repetition constraint may shrink the feasible domain and lead to
smaller objective gain. Plan your design accordingly.

Example
The example model is a two-dimensional simplified case of a bracing system for the facade of high-
rise buildings [17 (p. 349)]. The optimization problem consists in minimizing the structural compliance
under a volume fraction constraint of 0.4 using the Topology Optimization – Density Based method.

Example File

Download the following project file to examine the feature in more detail:

Project File (Pattern_Repetition_Bracing_System.wbpz):

Setup and Mesh

The environmental conditions are illustrated below. Note that the finite element model contains
44160 elements. A Fixed Support (A) is defined on the bottom edge of the domain and two horizontal
Force (B and C) loads, mimicking seismic loads, are applied at specific floors (in red).

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Structural Optimization Theory

The optimization setup is shown below. The left and right sides of the domain are excluded from the
optimization region.

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 Design Constraints Background

Here, as illustrated by the image of the left, is the optimized result without considering any design
constraints. As expected, most of the material is concentrated at the lower region, where resulting
moment and shear forces are higher. The density field is too low at high regions. AS shown by the
image of the right, the shape is modified at these regions for a Retained Threshold equal to 0.01.
The structural compliance equals 1.95443e-06.

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Structural Optimization Theory

Adding a Pattern Repetition constraint along the Z-axis, to obtain a shape that repeats at every
floor, results in the optimized shape shown below. As expected, the structural compliance increases
to 2.60075e-06 (+32.4%).

4.3. Local Design Restrictions

The Local Design Restriction (p. 335) object/feature enables you to apply targeted constraints to specific
regions of your model. These constraints help address manufacturing requirements, improve functional
performance, and support aesthetic objectives. This section outlines the feature’s purpose, offers guidance
for effective implementation, and summarizes current limitations.

Go to a section topic:
4.3.1. Non-Optimizable Regions
4.3.2. Bandwidth Constraints
4.3.3. Directional Morphing

4.3.1. Non-Optimizable Regions

When you specify a Local Design Restriction object as Non-Optimizable (Type = Non-Optimizable),
the application excludes the selected regions from the optimization process. This feature is supported
for all optimization methods. Depending on the method used:

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 Local Design Restrictions

• Topology Optimization (mixable, level-set, and density-based) and Materials Optimization: The
selected region retains forced material, as specified by the design restriction, preventing removal
during optimization.

• Shape Optimization and Topography Optimization: Nodes within the selected region are fixed
and cannot be moved.

• Lattice Optimization: The selected region is assigned a maximum specified density limit.

ANSYS recommends using this feature when the regions to be preserved are geometrically isolated
from the rest of the model—even if no loads or boundary conditions are applied to them.

Go to a section topic:

• Setup and Technical Details (p. 289)

• Non-Optimizable Case Study 1: Topology Optimization - Mixable Density (p. 290)

• Non-Optimizable Case Study 2: Materials Optimization (p. 294)

• Non-Optimizable Case Study 3: Lattice Optimization (p. 299)

Setup and Technical Details

Based on the selected Optimization Type (p. 44), you define the relevant properties of the Optimization
Region (p. 44) object as well as the properties of the Local Design Restriction as described in the
following table.

Table 4.3: Local Design Restriction Properties by Optimization Type

Method
Density/Mixable Shape/Topography Lattice Materials
Property Density/Level-Set Optimization Optimization Optimization
Material NA NA NA Specify the material
used for the Local
Design Restriction
selected regions.
Exclusion Inherited from the corresponding NA NA
Thickness properties of the Optimization Region
object.
Exclusion Ex- Inherited from the NA NA NA
tension corresponding
properties of the
Optimization Re-
gion object.[a]
Minim- NA NA Inherited from the NA
um/Maxim- corresponding
um Density properties of the
Optimization Re-
gion object.

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Structural Optimization Theory

Method
Density/Mixable Shape/Topography Lattice Materials
Property Density/Level-Set Optimization Optimization Optimization
Lattice Cell NA NA NA
Size
[a] Not supported for the Topology Optimization - Density Based method.

Non-Optimizable Case Study 1: Topology Optimization - Mixable Density

This case study examines the use of the Non-Optimizable option of the Local Design Restriction
feature using the Topology Optimization - Mixable Density method. The example comes from the
well-known GE Jet Engine Bracket Challenge. The objective of this optimization is to minimize struc-
tural compliance while satisfying a volume fraction constraint of 0.4.

Example File

Download and solve the following project file to examine the feature in more detail:

Project File ([Link]):

Set Up and Mesh

The environmental conditions are illustrated below. The finite element model includes 497,344
elements.

The upstream Static Structural system is configured with a Fixed Support (A) applied at the
four outer bolt holes, and a Force (B) applied at the two central through-holes.

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 Local Design Restrictions

No Local Design Restriction

The settings of the Exclusion Region properties are illustrated below.

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Structural Optimization Theory

This result shows the optimized shape without a specified Local Design Restriction. For this result,
the structural compliance equals 0.479754.

Local Design Restriction Included

In this example, two design restriction objects define the regions to be excluded as illustrated in
red when you select the Local Design Restriction and Optimization Region objects. Each object
specifies the Type property as Non-Optimizable.

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 Local Design Restrictions

As expected, the optimized shape changes significantly to accommodate these restrictions. Since
all defined regions must be covered by material, the design space is reduced. The structural
compliance increases by +5.3%.

Setting the Exclusion Extension property to Isotropic automatically modifies all exclusion regions
and leads to a slightly different optimized shape with similar performance.

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Structural Optimization Theory

Non-Optimizable Case Study 2: Materials Optimization

This case examines the application of a non-optimizable (Type = Non-Optimizable) Local Design
Restriction using the Materials Optimization method.

Example File

Download and solve the following project file to examine the feature in more detail:

Project File (Materials_Optimization_Bracket.wbpz):

The Optimization Region is specified using the following materials and a weak material representing
void.

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 Local Design Restrictions

The optimization problem is to minimize the structural compliance under:

• A volume fraction constraint of 0.5 for all materials.

• A Center of Gravity constraint so that the X-coordinate lies inside the interval [-0.1, -0.01].

Set Up and Mesh

The environmental conditions are illustrated below. The finite element model includes 29,210
elements.

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Structural Optimization Theory

The upstream Static Structural system is configured with a Pressure (A) applied to the center
opening and four Fixed Supports (B-D) in the outer openings.

Local Design Restrictions

The first Local Design Restriction includes regions covered by Stainless Steel.

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 Local Design Restrictions

The second Local Design Restriction includes a region covered by Structural Steel.

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Structural Optimization Theory

Optimized Shape

Here is the resulting optimized shape. You can see the correct placement of materials at the ex-
cluded regions.

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 Local Design Restrictions

Non-Optimizable Case Study 3: Lattice Optimization

This case examines the application of a non-optimizable (Type = Non-Optimizable) Local Design
Restriction using the Lattice optimization method.

Example File

Download and solve the following project file to examine the feature in more detail:

Project File (Lattice_Bracket.wbpz):

The Optimization Region includes a Titanium Alloy lattice of Cubic type, whose density is allowed
to vary inside the interval [0.2, 0.8]. The optimization problem is to minimize the structural compliance
under:

• A volume fraction constraint of 0.5.

• A Center of Gravity constraint so that the X-coordinate lies inside the interval [-0.1, -0.01].

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Structural Optimization Theory

Set Up and Mesh

The environmental conditions are illustrated below. The finite element model includes
29,210elements.

The upstream Static Structural system is configured with a Pressure (A) applied to the center
opening and four Fixed Supports (B-D) in the outer openings.

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 Local Design Restrictions

Local Design Restriction

The Exclusion Region includes all boundary conditions as well as the following additional Local
Design Constraint specified as Non-Optimizable.

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Structural Optimization Theory

Optimized Shape

The optimized shape is illustrated below. You can verify that the excluded regions are covered
by lattice material with the highest specified density.

4.3.2. Bandwidth Constraints

Available for the Shape Optimization and Topography Optimization, use the Free, Inward
Morphing, and Outward Morphing design restrictions to construct an area around the selected faces
(bandwidth) inside which selected nodes can be displaced. The following figure illustrates the basic
characteristics of the settings:

Free setting with a large value specified for the Total Move Limit.

Inward Morphing setting with a moderate value specified for the Total Move Limit.

Outward Morphing setting with large value specified for the Total Move Limit.

Free setting with moderate value specified for the Total Move Limit.

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 Local Design Restrictions

Go to a section topic:

• Setup and Technical Details (p. 303)

• Bandwidth Constraints Case Study 1: Shape Optimization Curved Cylinder (p. 304)

• Bandwidth Constraints Case Study 2: Shape Optimization Valve (p. 308)

• Bandwidth Constraints Case Study 3: Topography Optimization L-Sheet (p. 313)

Setup and Technical Details

The setup requires you to define the Type property for the Local Design Restriction and define the
Total Move Limit.

Property Optimization Method

Type Specify the Type property. The options enable you to move the nodes inwards (Inward
Morphing), outwards (Outward Morphing), or in both directions (Free).

Shape Optimization

"Inward" and "outward" refer to the interior/exterior of the initial body.

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Structural Optimization Theory

Property Optimization Method

Topography Optimization

Because the Optimization Region is not a solid body, "inward" and "outward" refer
to the corresponding sides of your selection. The green highlight of the selected
face indicates the outward side.

Total This value defines the size of the domain inside which selected nodes can be displaced.
Move
Lim-
it

Important:

The Optimization Region object also includes a Total Move Limit property. The value
you enter for the Total Move Limit in the Local Design Restriction object cannot exceed
this limit. If it does, the system automatically resets it to the value defined in the Optimiz-
ation Region object. However, a node can be displaced by more than the value specified
in this property without violating the corresponding Local Design Restriction. Therefore,
the two concepts are not equivalent. This situation is illustrated below. A Local Design
Restriction specified as Free is defined over an edge (shown in red). The displaced edges
appear as dashed contours. The final node displacement can exceed the value of the Total
Move Limit property without violating the constraint.

Bandwidth Constraints Case Study 1: Shape Optimization Curved Cylinder

This case study examines the application of bandwidth constraints in a Shape Optimization analysis
using a curved cylinder. The objective is to minimize structural compliance while satisfying a Maximum
Member Size constraint of 0.01 m.

Example File

Download and solve the following project file to examine the feature in more detail:

Project File (Shape_Optimization_Curved_Cylinder.wbpz):

Set Up and Mesh

The mesh and environment conditions are illustrated below. The finite element model contains
116,296 elements.

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 Local Design Restrictions

As illustrated, the upstream Static Structural system is configured with a Fixed Support (A) and
a Force (B).

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Structural Optimization Theory

Bandwidth constraints are applied by assigning the specifying a Local Design Restriction to the
highlighted optimizable surface. For each Local Design Restriction type (Free and Inward
Morphing), the Total Move Limit is set to 4 mm.

Free Morphing

This example specifies Free morphing. As illustrated, the optimized shape can move in both dir-
ections—inward and outward—up to the value specified in the Total Move Limit property.

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 Local Design Restrictions

The structural compliance for this optimized shape equals 49.451.

Inward Morphing

Switching to Inward Morphing, the shape can no longer move outwards. This leads to a significant
loss of design freedom and a corresponding loss of performance.

The structural compliance equals 120.534 (+143,7%).

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Structural Optimization Theory

Bandwidth Constraints Case Study 2: Shape Optimization Valve

This case study examines the application of bandwidth constraints in a Shape Optimization analysis
using an exhaust value. The objective is to minimize the Equivalent (von-Mises) Stress, under a
symmetry constraint (XY-Plane) and different bandwidth constraints that have the same Total Move
Limit (2.5mm).

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 Local Design Restrictions

Example File

Download and solve the following project file to examine the feature in more detail:

Project File (Shape_Optimization_Valve.wbpz):

Set Up and Mesh

The mesh and environment conditions are illustrated below. The finite element model contains
239,076 elements.

As illustrated, the upstream Static Structural system is configured with a Fixed Support (A),
three Displacements (B/C/D), and a Pressure (E).

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Structural Optimization Theory

Static Structural Analysis

For reference, the Equivalent Stress result from the upstream Static Structural analysis is illus-
trated below.

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 Local Design Restrictions

Free Morphing

Here is the Equivalent Stress result with the Local Design Restriction specified as Free. The
second image shows a User Defined Result of the optimized stress distribution and the total
node movement. The stress criterion is 1.82402e+08.

Inward Morphing

Here is the Equivalent Stress result with the Local Design Restriction specified as Inward
Morphing. The second image shows a User Defined Result of the optimized stress distribution

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Structural Optimization Theory

and the total node movement. The stress criterion equals 1.92901e+08. An improvement of
(+5.8%).

Outward Morphing

Here is the Equivalent Stress result with the Local Design Restriction specified as Outward
Morphing. The second image shows a User Defined Result of the optimized stress distribution
and the total node movement. The stress criterion equals 2.06922e+08. An improvement of
(+13.4%).

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 Local Design Restrictions

Bandwidth Constraints Case Study 3: Topography Optimization L-Sheet

This case study examines the application of bandwidth constraints in a Topography Optimization
analysis using a thin L-type bracket. The objective is to minimize the structural compliance while al-
lowing the mass to increase at most 5%.

Each environment includes a Local Design Restriction with the indicated Type and a Total Move
Limit property setting of 1cm.

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Structural Optimization Theory

Example File

Download and solve the following project file to examine the feature in more detail:

Project File (Topography_Optimization_L_Sheet.wbpz):

Set Up and Mesh

The mesh and environment conditions are illustrated below. The finite element model contains
4,902 shell elements.

As illustrated, the upstream Static Structural system is configured with a Fixed Support (A) and
a Force (B).

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 Local Design Restrictions

Exclusion Regions & Local Design Restriction

Each of the three environments includes two Local Design Restrictions specified as Exclusion
Region objects that are defined as follows (outer edges and boundary conditions).

Each of the three environments also includes a Local Design Restriction specified as follows.

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Structural Optimization Theory

Free Morphing

When solved, Free morphing provides maximum flexibility with respect to shape changes. Note
how the shape moves in both directions. The structural compliance equals 0.0486367.

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 Local Design Restrictions

Inward Morphing

For Inward Morphing, the shape can only move to the internal side. In this case, structural
compliance increases significantly, by +166.3%.

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Structural Optimization Theory

Outward Morphing

For Outward Morphing, the shape can move only to the external side. Despite the additional
restriction with respect to the Free option, the structural compliance improves by -10.4%. This
validates the existence of abundant local minima.

Or?

For Outward Morphing, the shape can move only toward the external side. Despite this additional
restriction compared to the Free option, the structural compliance improves by (negative?) 10.4%.
This indicates the presence of multiple local minima in the design space.

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 Local Design Restrictions

Simultaneous Free, Inward, and Outward Morphing

You can also combine different types of bandwidth constraints, defined over different regions of
the shape. As illustrated, in this example, we combine Free, Outward Morphing, and Inward
Morphing.

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Structural Optimization Theory

The structural compliance increases merely by +1.1% compared to the Free morphing.

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 Local Design Restrictions

4.3.3. Directional Morphing

Using the Type property options In-Plane, Along Direction, and Along Normal Morphing of a
Local Design Restriction enable you to restrict node movement along corresponding directions.
These options are only for the Shape Optimization and Topography Optimization methods.

The figure below illustrates different restrictions scenario. For the mesh nodes illustrated in red:

• The black coordinate shows no local constraint specified. The node can move in any of the
three directions.

• The pink directions show the displacement for the In-Plane Morphing option. The node can
only move on the original surface.

• The green directions show the displacement for the Along Direction Morphing option. The
node can only move along the direction you specify.

• The blue directions show the displacement for the Along Normal Morphing option. The node
can only move along the normal of the original surface. That is, the normal direction is not
updated during the optimization process. The normal direction at nodes is computed as an
average of the normal vectors of their adjacent faces.

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Structural Optimization Theory

Setup and Technical Details

For the supported optimization methods, note the following setup requirements to define the Local
Design Restriction.

Property Description
Type For the Topography Optimization method and the Along Normal Morphing option, the
normal direction is oriented towards the outward side of the faces, indicated by the green
highlight when selected.
Axis This property is available only for the Along Direction Morphing option.

Recommendations
Note the following:

• When using the In-Plane Morphing option for non-smooth regions, the following cases may
occur:

– If a node is attached to two planar surfaces that form a sharp angle, the node can move
only along the direction of their common edge.

– If a node is attached to more than two planar surfaces that form sharp angles, for ex-
ample, corner nodes, the node cannot move.

• Nodes in regions that include multiple local design restrictions are handled as follows:

– If at least one non-optimizable Local Design Restriction exists, the node is blocked.

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 Local Design Restrictions

– If one Local Design Restriction specified using the Along Direction Morphing option
exists:

→ And there is also a second Local Design Restriction of the same type and the
directions are not aligned, then the node is blocked.

→ And a second Local Design Restriction specified using the In-Plane Morphing
option exists:

• And the specified Axis lies inside the specified plane, then the In-Plane
Morphing Local Design Restriction is neglected.

• If the specified Axis does not lie inside the specified plane, then the node is
blocked.

– If two Local Design Restrictions specified using the In-Plane Morphing option exist:

→ And the specified planes are identical, then the second Local Design Restriction
is neglected.

→ And the specified planes are not identical, then the Local Design Restrictions
specified using the In-Plane Morphing option are neglected and an Local Design
Restriction specified using the Along Direction Morphing option is imposed in
the direction of their crossing line.

Example
This example examines the application of directional morphing constraints using the Shape Optim-
ization method. The example model is a C-type bracket. The optimization problem consists of min-
imizing structural compliance while preventing the total mass from increasing.

Example File

Download and solve the following project file to examine the feature in more detail:

Project File (Shape_Optimization_C_Type_Bracket.wbpz):

Set Up and Mesh

The mesh and environmental conditions are illustrated below. The finite element model contains
89,823 elements.

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Structural Optimization Theory

As illustrated, the upstream Static Structural system is configured with a Fixed Support (A) and
a Force (B).

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 Local Design Restrictions

No Directional Morphing Constraints

First, no directional morphing constraints is imposed on part of the body, shown in blue. The
optimized shape appears as shown. The structural compliance equals 5.6792e-04.

Along Direction Morphing

One can verify from the previous example that, in the absence of additional design restrictions,
it is possible for an initially castable shape to become non-castable in some direction. The optimized
shape has lost its castability in the Y-direction due to undercuts formed in the upper and lower
sides of the horizontal part.

To prevent this situation, impose a Local Design Restriction of Type = Along Direction Morphing
and select the Y-Axis as axis for shape modifications.

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Structural Optimization Theory

Here is the optimized shape.

You can verify that the shape evolves along the Y-direction, preventing the formation of undercuts.
The structural compliance slightly increases to 5.93954e-04 (+0.8%).

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 Local Design Restrictions

Along Direction Morphing and In-plane Morphing

An additional design freedom that respects castability in the Y-direction can be provided by letting
the three inner surfaces move in-plane, as shown below.

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Structural Optimization Theory

The optimized shape and the shape evolution combining Along Direction and In-plane
Morphing local Design Restriction for different regions of the same shape appears below.

The shape retains castability in the Y-direction and structural compliance equals 5.53491e-04.

Along Direction vs Along Normal Morphing

Now, examine the difference between Along Direction Morphing and Along Normal Morphing.
For this, we allow only a small part of the lower side to move, as shown below.

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 Local Design Restrictions

Using Type = Along Direction Morphing in the Z-Axis, all nodes are forced to move only in the
Z-direction.

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Structural Optimization Theory

The optimized shape and the shape evolution are shown here. Structural compliance equals
6.40487e-04.

Using Type = Along Normal Morphing, all nodes are forced to move only in the direction of the
exterior normal vector of the original surface.

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 Local Design Restrictions

For the curved parts, this direction is different than the Z-Axis, while for the flat part directions
coincide. The optimized shape and its shape evolution are shown below. Structural compliance
equals 6.36056e-04.

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Chapter 5: Object Reference
Specifications are provided for the following Mechanical application objects that are unique to Struc-
tural Optimization simulations:
5.1. Design Constraint
5.2. Local Design Restriction
5.3. Manufacturing Constraint
5.4. Objective
5.5. Optimization Region
5.6. Response Constraint

5.1. Design Constraint

Specifies certain manufacturing-based limitations to help alleviate design problems.

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Object Reference

Object
Properties (p. 334)

Tree
Dependencies (p. 334)

Insertion
Methods (p. 335)

Right-click
Options (p. 335)

Additional
Related
Information (p. 335)

Object Properties
The Details Pane properties for this object are examined in the Define Design Constraints (p. 83) section.

Tree Dependencies
• Valid Parent Tree Object: Structural Optimization Environment.

• Valid Child Tree Objects: No supported child objects.

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 Local Design Restriction

Insertion Methods
To add a Design Constraint object, highlight the Structural Optimization environment and either:

• Select Design Constraint > [desired Design Constraint] from the Environment Context Tab.

• Right-click and select Insert > [desired Design Constraint].

Right-click Options
In addition to common right-click options, relevant right-click options for this object include:

• Insert > [Various Structural Optimization options]

• Commands

• Suppress/Unsuppress

Additional Related Information

See the following sections for more information:

• Define Design Constraints (p. 83)

• Structural Optimization Analysis Guide (p. 1)

5.2. Local Design Restriction

Specify additional design restrictions on geometric entities or geometry- or element-based Named Se-
lections of your model.

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Object Reference

Object
Properties (p. 336)

Tree
Dependencies (p. 338)

Insertion
Methods (p. 338)

Right-click (p. 338)

Additional
Related
Information (p. 338)

Object Properties
The Details Pane for this object includes the following properties.

Category Properties/Options/Descriptions
Restric- Define By[a]: Specify as Geometry Selection (default) or Named Selection.
tion Re-
gion Geometry: Visible when the Scoping Method is set to Geometry Selection. Use
selection filters to pick geometry, click in the Geometry field, then click Apply.
Based on the specifications you make below, scoping requirements may apply.

Named Selection: Visible when the Scoping Method is set to Named Selection.
This field provides a drop-down list of available user-defined Named Selections.
Based on the specifications you make below, scoping requirements may apply.
Defini- Type: Use this property to define additional restrictions. Options include:
tions
• Non-Optimizable (default): The application does not optimize the selected
regions (the degrees of freedom). For the topology optimization methods

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 Local Design Restriction

Category Properties/Options/Descriptions
this means the selection will have forced material. For the Shape Optimiz-
ation and Topography methods, this means that the nodes cannot be
moved.

• In-plane Morphing: Supported for the Shape Optimization method and

face selections only, the application does not move any nodes vertically with
respect to the original face. That is, the nodes remain "in the plane."

Shape Optimization and Topography Methods Only

Use the following options for the Shape Optimization and Topography
methods:

• Along Direction Morphing: The application only displaces the nodes

of the specified selection along a defined coordinate direction.

• Along Normal Morphing: Nodes of the selection can only be displaced

along the initial normal of the surface.

• Free: The application can displace nodes in any direction up to the

distance specified by the Total Move Limit property.

• Inward Morphing: The application can only displace nodes inward up

to the limit specified by the Total Move Limit property.

• Outward Morphing: The application can only displace nodes outward

up to the limit specified by the Total Move Limit property.

Suppressed: Include or exclude the object in the analysis.

Location Coordinate System: Select a desired coordinate system from the drop-down list.
and Ori-
entations Axis: Select the axis along which displacement is allowed. Options include X Axis
(Along (default), Y Axis, and Z Axis.
Direction
Morphing
option
only)
Optimiza- Total Move Limit: Define the maximum distance each node of the selection
tion Op- can move. Options include Program Controlled and Manual.
tion
(Free, Value: This property displays when you set the Total Move Limit property to
Outward Manual. Manually enter the maximum distance a node can move.
Morphing,
and
Inward
Morphing
options
only)
[a]

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Object Reference

[a]
Limitation
If your simulation includes Symmetry, you must scope the Local Design Restriction object to each side of the symmetrical
body so that the application respects the symmetry and correctly processes the exclusion.

Tree Dependencies
• Valid Parent Tree Objects: Optimization Region object.

• Valid Child Tree Object: Comment, Figure, and Image.

Insertion Methods
Highlight the Optimization Region object and select the Local Design Restriction option from the
Optimization group on the Environment Context tab. You can also right-click the Optimization Region
object and select Insert > Local Design Restriction.

Right-click Options
Relevant right-click options for this object are in the common right-click options list.

Additional Related Information

See the Define Optimization Method and Regions (p. 44) section for more information.

5.3. Manufacturing Constraint

Specifies constraints and other restrictions to ensure manufacturable designs during a Structural Optim-
ization (p. 1) analysis.

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 Manufacturing Constraint

Object
Properties (p. 339)

Tree
Dependencies (p. 339)

Insertion
Methods (p. 340)

Right-click
Options (p. 340)

API
Reference (p. 340)

Additional
Related
Information (p. 340)

Object Properties
The Details Pane properties for this object are examined in the Define Manufacturing Constraints (p. 72)
section.

Tree Dependencies
• Only one Manufacturing Constraint object is permitted for each analysis.

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Object Reference

• Valid Parent Tree Object: Structural Optimization Environment.

• Valid Child Tree Objects: No supported child objects.

Insertion Methods
To add a Manufacturing Constraint object, highlight the Structural Optimization environment and
either:

• Open the Manufacturing Constraint drop-down menu on the Environment Context tab and
select a desired constraint type (p. 73).

• Right-click and select Insert > constraint type (p. 73).

Right-click Options
In addition to common right-click options, relevant right-click options for this object include:

• Insert > [Various environment (p. 3) options]

• Suppress/Unsuppress

API Reference
See the Manufacturing Constraint section of the ACT API Reference Guide for specific scripting inform-
ation.

Additional Related Information

See the Define Manufacturing Constraints (p. 72) section for more information.

5.4. Objective
Specifies the structural optimization goal. A Structural Optimization (p. 1) analysis can have only one
Objective object in the tree. The application inserts this object automatically when you create a
Structural Optimization analysis.

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 Objective

Object Properties (p. 341)

Tree Dependencies (p. 341)

Insertion Methods (p. 341)

Right-click Options (p. 342)

API Reference (p. 342)

Additional Related
Information (p. 342)

Object Properties
The Details Pane properties for this object are examined in the Define Design Objectives (p. 55) section.

Tree Dependencies
• Valid Parent Tree Object: Structural Optimization Environment.

• Valid Child Tree Objects: No supported child objects.

Insertion Methods
The application automatically inserts this object. To add additional Objective objects, highlight the
Structural Optimization environment and:

• Select Objective from the Environment Context.

• Right-click and select Insert > Objective.

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Object Reference

Right-click Options
In addition to common right-click options, relevant right-click options for this object include:

• Insert > [Various Structural Optimization (p. 1) options]

• Commands Objects

API Reference
See the Objective section of the ACT API Reference Guide for specific scripting information.

Additional Related Information

See the Objective (p. 55) section in the Structural Optimization Analysis Guide documentation.

5.5. Optimization Region

Specifies the geometric entity on a model that will be optimized using a Structural Optimization (p. 1)
analysis. The application inserts this object automatically when you create a Structural Optimization
analysis.

Exclusion Region

The Exclusion Region object is an insertable child object of the Optimization Region object. The Ex-
clusion Region object enables you to specify additional geometric entities (body, face, edge, and ele-
ments) and/or geometry- or element-based Named Selections to the scoping of the Exclusion Region
of the Optimization Region object.

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 Optimization Region

Object
Properties (p. 343)

Tree
Dependencies (p. 343)

Insertion
Methods (p. 344)

Right-click
Options (p. 344)

API
Reference (p. 345)

Additional
Related
Information (p. 345)

Object Properties
The Details Pane properties for this object are examined in the Define Optimization Method and Re-
gions (p. 44) section of the Structural Optimization Analysis Guide.

Tree Dependencies
• Valid Parent Tree Object: Structural Optimization Environment.

• Valid Child Tree Object: Local Design Restriction.

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Object Reference

Insertion Methods
• Select the Optimization Region option from the Optimization group on the Environment Context
tab.

• Right-click the Structural Optimization object and select Insert > Optimization Region.

• Select either the Environment or the Optimization Region object, right-click in the Geometry window,
and select Insert > Optimization Region.

• Right-click an existing Optimization Region object and select Insert > Optimization Region.

Right-click Options
In addition to common right-click options, relevant right-click options for this object include:

• Insert >

– Local Design Restriction (p. 49)

– Optimization Region (p. 44)

– Objective

– Volume Constraint

– Mass Constraint

– Center of Gravity Constraint

– Moment of Inertia Constraint

– Compliance Constraint (Static Structural Analysis)

– Displacement Constraint (Static Structural Analysis)

– Reaction Force Constraint (Static Structural Analysis)

– Global von-Mises Stress Constraint (Static Structural Analysis)

– Local von-Mises Stress Constraint (Static Structural Analysis)

– Criterion Constraint (Static Structural Analysis)

– Member Size

– Pull out Direction

– Extrusion

– AM Overhang Constraint

– Housing

– Complex Index

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 Response Constraint

– Cyclic Repetition

– Symmetry

– Uniform

– Pattern Repetition

– Temperature Constraint (Steady-State Thermal Analysis)

– Natural Frequency Constraint (Modal Analysis)

– Commands Objects

• Group Similar Objects

API Reference
See the Optimization Region section of the ACT API Reference Guide for specific scripting information.

Additional Related Information

• Define Optimization Method and Regions (p. 44)

• Structural Optimization Overview (p. 1)

5.6. Response Constraint

Determines a condition that the optimization must respect, such as specifying a mass to retain. It is
defined as one of the following and availability of the options depends upon the upstream analysis
type:

• Mass Constraint (default)

• Volume Constraint

• Global Stress Constraint (Static Structural Analysis)

• Natural Frequency Constraint (Modal Analysis)

• Local von-Mises Stress Constraint (Static Structural Analysis)

• Displacement Constraint (Static Structural Analysis)

• Reaction Force Constraint (Static Structural Analysis)

• Compliance Constraint (Static Structural Analysis)

• Center of Gravity Constraint

• Moment of Inertia Constraint

• Temperature Constraint (Steady-State Thermal Analysis)

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Object Reference

• Criterion Constraint (Static Structural Analysis)

This constraint is required for a Structural Optimization (p. 1) analysis. The application inserts this object
automatically when you create a Structural Optimization analysis. The default response constraint is
a Mass Constraint object.

Object Properties (p. 346)

Tree Dependencies (p. 346)

Insertion Methods (p. 347)

Right-click Options (p. 347)

API Reference (p. 348)

Additional Related
Information (p. 348)

Object Properties
The Details Pane properties for this object are examined in the Define Response Constraints (p. 62)
section.

Tree Dependencies
• Valid Parent Tree Object: Structural Optimization Environment.

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 Response Constraint

• Valid Child Tree Objects: Comment, Figure, and Image.

Insertion Methods
The application automatically inserts this object as a Mass Constraint. To add additional constraint
objects, highlight the Structural Optimization environment and either:

• Select the desired constraint from the Response Constraint drop-down menu on the Environment
Context.

• Right-click the Environment object or within the Geometry window and select Insert > [desired
constraint].

Right-click Options
In addition to common right-click options, relevant right-click options for this object include:

• Insert >

– Optimization Region

– Objective

– Mass Constraint

– Volume Constraint

– Natural Frequency Constraint (Modal Analysis)

– Global Stress Constraint (Static Structural Analysis)

– Local von-Mises Stress Constraint (Static Structural Analysis)

– Displacement Constraint (Static Structural Analysis)

– Reaction Force Constraint (Static Structural Analysis)

– Compliance Constraint (Static Structural Analysis)

– Center of Gravity Constraint

– Moment of Inertia Constraint

– Temperature Constraint (Steady-State Thermal Analysis)

– Criterion Constraint (Static Structural and Modal Analysis)

– Member Size

– Pull out Direction

– Extrusion

– Cyclic

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Object Reference

– Symmetry

– Uniform

– Pattern Repetition

– AM Overhang Constraint

– Commands

• Suppress/Unsuppress

API Reference
See the Response Contraint section of the ACT API Reference Guide for specific scripting information.

Additional Related Information

See the following sections for more information:

• Define Response Constraints (p. 62)

• Structural Optimization (p. 1)

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Chapter 6: Bibliography
[1] Bendsøe, M. P., & Kikuchi, N. (1988). Generating optimal topologies in structural design using a ho-
mogenization method. Computer Methods in Applied Mechanics and Engineering. 71(2), 197–224.

[2] Bendsøe, M. P., & Sigmund, O. (2003). Topology Optimization: Theory, Methods, and Applications.
Berlin, DE: Springer.

[3] Murat, F., & Tartar, L. (1985). Calcul des Variations et Homogénéisation. D. Bergman & al. (Eds.), Les
Méthodes de l’Homogénéisation: Théorie et Applications en Physique (pp. 319-369). Coll. Dir. Etudes et
Recherches EDF. 57. Paris, FR: Eyrolles.

[4] Dapogny, C., & Frey, P. (2012). Computation of the signed distance function to a discrete contour
on adapted triangulation. Calcolo. 49, 193–219

[5] Allaire, G., Jouve, F., & Toader. A.-M. (2004). Structural optimization using sensitivity analysis and a
level-set method. Journal of Computational Physics. 194, 363–393

[6] Bui, C., Dapogny, C., & Frey, P. (2012). An accurate anisotropic adaptation method for solving the
level set advection equation. International Journal for Numerical Methods in Fluids.

[7] Osher, S., & Sethian, J. A. (1988). Fronts propagating with curvature-dependent speed: Algorithms
based on Hamilton-Jacobi formulations. Journal of Computational Physics. 79(1), 12–49.

[8] Allaire, G., Dapogny, C., & Jouve, F. (2021). Shape and Topology Optimization. A. Bonito & R. Nochetto
(Eds.), Geometric Partial Differential Equations, Part II (pp. 1–132). Handbook of Numerical Analysis. 22.
Elsevier.

[9] Allaire, G., & Schoenauer, M. (2007). Conception optimale de structures. Berlin, DE: Springer.

[10] Shimoda, M., & Liu, Y. (2014). A non-parametric free-form optimization method for shell structures.
Structural and Multidisciplinary Optimization. 50, 409–423.

[11] Cheng, L., Zhang, P., Biyikli, E., Bai, J., Robbins, J., & To, A. (2017). Efficient design optimization of
variable-density cellular structures for additive manufacturing: theory and experimental validation.
Rapid Prototyping Journal. 23(4), 660–677.

[12] Allaire, G. (1992). Homogenization and two-scale convergence. SIAM Journal on Mathematical
Analysis. 23(6), 1482–1518.

[13] Allaire, G., Jouve, F., & Michailidis, G. (2016). Thickness control in structural optimization via a level
set method. Structural and Multidisciplinary Optimization. 53, 1349–1382.

[14] [Fernández, E., Yang, K. K., Koppen, S., Alarcón, P., Bauduin, S., & Duysinx, P. (2020). Imposing min-
imum and maximum member size, minimum cavity size, and minimum separation distance between
solid members in topology optimization. Computer Methods in Applied Mechanics and Engineering.
368, Article 113157.

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Bibliography

[15] G. Allaire, C. Dapogny, R. Estevez, A. Faure, G. Michailidis, Structural optimization under overhang
constraints imposed by additive manufacturing technologies, Journal of Computational Physics, Volume
351, 2017, Pages 295-328.

[16] Matthijs Langelaar, Topology optimization of 3D self-supporting structures for additive manufacturing,
Additive Manufacturing, Volume 12, Part A, 2016, Pages 60-70.

[17] L.L. Stromberg, A. Beghini, W.F. Baker, G.H. Paulino, Topology optimization for braced frames:
Combining continuum and beam/column elements. Engineering Structures, 2012.

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