Topology optimization, using both physic-based approaches and deep learning surrogates, serves as a cornerstone for generative design agents in cyber-manufacturing systems. While deep learning surrogates have gained widespread adoption due to their speed in online design generation, this work demonstrates their vulnerability under input perturbations. In this work, we present a mechanics-grounded reliability evaluation framework that formulates an adversarial agent targeting the generative design models. We investigate a strictly non-intrusive threat model where bounded perturbations are introduced exclusively to the initial-density channel, while physical boundary conditions, compliance-gradient channels, network architectures, and solver routines remain intact. Evaluating surrogate models across U-Net, convolutional, and generative architectures with varying physics-gradient conditioning depths demonstrates that bounded initialization noise can cause catastrophic mechanical failure, increasing compliance by multiple orders of magnitude through severed load paths and disconnected supports. Furthermore, we discover that incorporating richer physics-gradient conditioning in the deep learning surrogates does not guarantee monotonic robustness across surrogate families. Finally, physics-in-the-loop recovery demonstrates that initializing the classical SIMP optimizer with perturbed topologies mitigates design performance degradation, having a high probability of restoring compliance to near-baseline levels across tested instances. These findings demonstrate that learned surrogates should serve as physics-verified initializers instead of replacing physics-based solvers entirely in a resilient cyber-manufacturing system. Moreover, the proposed adversarial agent provides a foundation for future training generative design agents robust against noise and targeted perturbations.
Thermo-mechanical compliant devices are commonly designed with small-strain linear elasticity and temperature-independent material properties, even though they might operate hundreds of kelvin above ambient where both assumptions are questionable. In this work, we quantify the effect and cost of each assumption in multi-material topology optimization of thermally actuated compliant devices. To this end, we introduce a physics-informed, simultaneous analysis-and-design framework with (i) a finite-strain quadratic-Hencky (logarithmic-strain) constitutive model whose isotropic thermal eigenstrain admits an exact additive split in log-strain space, and (ii) temperature-dependent conductivity, thermal expansion, and elastic moduli for a titanium--copper--steel material system. We optimize a thermal actuator and a thermal gripper at three design temperatures under both a baseline model and the full physics, subject to mass and manufacturability constraints. Every converged design is re-evaluated by verified nonlinear finite element solvers in the full factorial of constitutive law and property model. The comparison between the two factors reveals that the constitutive law is the decisive modeling choice: These devices work as linkages where linear kinematics mistakes rotation for compressive strain; its error therefore grows with the design temperature and concentrates on the very layouts that exploit rotation best. Because a linear optimizer also steers away from the rotation-rich mechanisms that would expose this bias, the model can deceptively appear trustworthy when validated against its own designs. Designing with the full physics yields consistently stronger and more temperature-robust devices at a modest increase in design-time cost.
Topology optimisation (TO) often requires repeated finite element analysis and sensitivity-based material updates, which can be costly when multiple candidate designs are needed under varying physical and design conditions. Generative TO offers a route to rapid design exploration, but existing models may rely on adversarial training, long reverse-diffusion sampling, or external guidance to maintain structural feasibility and physical consistency. This study develops a flow matching-based topology optimisation (FMTO) framework for conditional topology generation. Linear FMTO is first formulated as an endpoint-based baseline by interpolating between a Gaussian source field and the BESO reference topology. To introduce mechanically meaningful intermediate states, a trajectory-aware FMTO formulation is proposed, where volume-fraction-indexed BESO states are used to construct the probability path and target velocity field. This incorporates physics-guided optimisation history into generative flow learning without adding inference-time optimisation. A path--velocity mismatch analysis explains why moderate trajectory weighting can improve generation stability, whereas excessive guidance may over-constrain the learned transport. Numerical examples show that FMTO generates diverse topology candidates with improved compliance-related performance, volume-fraction satisfaction, topology fidelity, and substantially fewer sampling steps than a diffusion-based baseline. Under limited training data, trajectory-aware FMTO achieves the best overall performance with a moderate trajectory weight. Studies on trajectory-anchor density and three-dimensional topology generation further demonstrate the influence of path design and the applicability of the proposed framework beyond two-dimensional problems.
Deep generative models offer a promising paradigm for topology optimization, enabling rapid design exploration. However, these approaches lack intrinsic physics guidance, often leading to poor generalizability across unseen boundary conditions and the formation of floating material artifacts. To address these limitations, we propose Hierarchical Physics-Guided Diffusion (HPG-Diff), a novel diffusion framework that enforces physics consistency through two synergistic mechanisms. First, we introduce a hierarchical physics-guided strategy that aligns different precomputed physics features with the denoising process, guiding material distribution toward optimal load paths to enhance generalizability. Second, we propose a floating material suppression loss as a differentiable connectivity constraint inspired by thermal conduction to improve topological connectivity. By simulating a virtual heat propagation process from load positions, this mechanism explicitly penalizes floating material during training. Quantitative evaluations demonstrate that HPG-Diff achieves average compliance errors of 0.87% (in-distribution) and 5.29% (out-of-distribution), while reducing floating material ratios to 2.90% and 2.44%, respectively. Furthermore, case studies on a 3:1 rectangular domain, including cantilever and bridge benchmarks, provide preliminary evidence that lightweight LoRA fine-tuning with a small dataset can support the adaptation of HPG-Diff to rectangular non-square domains.
This work proposes an element-based Convolutional Neural Network (CNN) to accelerate density-based Topology Optimization (TO), termed eCNNTO. TO generally undergoes a large number of iterations, where finite element analysis is performed in every iteration, leading to the efficiency bottleneck especially when dense meshes are used to achieve high-resolution designs. To address this limitation, eCNNTO is proposed to build upon Kallioras et al. (2020), where a Deep Belief Network (DBN) was trained for every element to predict its near-optimal density from its early history, thereby skipping the great majority of iterations and significantly accelerating the TO procedure. However, the method lacks spatial correlations among neighboring elements and may lead to disconnected features in the final structure. The proposed method employs CNN with residual connections to address this issue. On top of it, a novel training strategy is introduced to further enhance the optimization efficiency, where the training dataset consists of the final stage density histories rather than early ones. This change can also help reduce the required training data size. eCNNTO requires only a small dataset to train and yet it can be generalized to problems with largely different boundary conditions, loading cases, design domain geometries, mesh resolutions, as well as non-design domains. In the end, the generalization capabilities and efficiency of eCNNTO are demonstrated through a variety of examples in two and three dimensions, achieving up to 90% and 97% reduction of iterations, respectively.
Haolin Li, Yuyang Miao, Menglei Li +9cs.AI cond-mat.mtrl-sci cs.LG
Architected metamaterials derive their functions from structure, creating vast opportunities to program physical responses through topology design. However, existing design methods are often tailored to individual design problems, making limited use of topology knowledge for effective and broadly applicable design as objectives, constraints, and physical functions change. Here we introduce Generative Topology Optimization (GenTO), a unified framework that turns a learned topology prior into a reusable design engine. GenTO trains a diffusion model on a large full-order topology dataset and then iteratively steers the resulting topology distribution toward task-specific high-performing regions using user-defined physical objectives and constraints. This shifts the object of optimization from a single structure to a task-adapted topology distribution. Across topology design problems spanning thermal extremization, multi-objective morphology control, property-targeted auxetic design, and vibration transmission design, GenTO reuses pretrained topology priors for heterogeneous tasks, preserves structural diversity, and reaches high-performing solutions supported by numerical benchmarks and experimental validation. These results establish reusable topology knowledge as a unified principle for effective and scalable architected metamaterial design.
Mohammad Rashed, Duarte F. Valoroso Madeira, Babak Gholami +3cs.LG cs.AI cs.CE
Surrogate models for topology optimization (TO) exhibit highly variable out-of-distribution (OOD) generalization under distribution shifts such as changing loads or boundary conditions, yet the source of this variability remains unclear. We hypothesize that OOD performance is governed by how much information the conditioning signal preserves about the adjoint sensitivity (reduced gradient) that drives classical TO. Modeling the TO pipeline as a causal Markov chain, the Data Processing Inequality establishes that, under this abstraction, the sensitivity field is an information-theoretically optimal conditioning signal for topology prediction. However, computing exact adjoint sensitivities can be expensive or unavailable in practice; we observe that certain physical fields can approximate sensitivities through monotone transformations. To formalize this, we introduce \textbf{pseudo-sensitivities} to characterize which fields enable generalization versus those that are information-poor. We then show that a sensitivity-conditioned Bernoulli flow-matching generator empirically confirms these predictions: conditioning on sensitivities yields state-of-the-art OOD performance, while increasingly distant physical fields degrade toward raw parameter conditioning. Results hold across structural TO benchmarks under load shifts and our new CFD-TO dataset under boundary-condition shifts such as multi-outlet configurations. Code and datasets are available at https://tum-pbs.github.io/topotransformer/ .