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<p>Three-dimensional (3D) continuous fiber reinforced composite (CFRC) curved thin-walled structures are common and crucial in aviation, aerospace, and other high-end equipment. However, the topology optimization method is as yet limited. This study proposes a novel 3D-oriented concurrent design framework integrating boundary first flattening (BFF) conformal mapping and level-set and stream function-based parallel topology optimization algorithms to optimize the topological layouts and fiber paths of CFRC curved thin-walled structures. Specifically, the framework employs the BFF algorithm to map the 3D curved physical domain into a 2D parameter domain for dimensionality reduction. In the parameter domain, the level-set function and stream function serve as structural descriptors to characterize the topology layout and fiber paths, respectively, so as to concurrently optimize the CFRC curved thin-walled structures. Notably, key innovations include: (1) A tangent mapping transformation mechanism between physical space and parameter space is proposed for accurate fiber orientation calculation; (2) A resampling-based symmetry technique is presented to reduce optimization variable dimensionality while avoiding suboptimal local minima. Three 3D cases (cylinder, hemisphere, and tee-branch pipe) validated the efficiency of the proposed framework in handling curved thin-walled composites with complex geometries. This work pioneers a new pathway for optimizing 3D CFRC curved thin-walled structures, which is significant for engineering structural innovation.</p>

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Three-dimensional topology optimization for continuous fiber reinforced composite thin-walled structures

  • 期刊论文

  • 发表日期：

    2026年1月8日

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  • Guixing Li,
  • Xiaochong Wang,
  • Yuan Chen

摘要

Three-dimensional (3D) continuous fiber reinforced composite (CFRC) curved thin-walled structures are common and crucial in aviation, aerospace, and other high-end equipment. However, the topology optimization method is as yet limited. This study proposes a novel 3D-oriented concurrent design framework integrating boundary first flattening (BFF) conformal mapping and level-set and stream function-based parallel topology optimization algorithms to optimize the topological layouts and fiber paths of CFRC curved thin-walled structures. Specifically, the framework employs the BFF algorithm to map the 3D curved physical domain into a 2D parameter domain for dimensionality reduction. In the parameter domain, the level-set function and stream function serve as structural descriptors to characterize the topology layout and fiber paths, respectively, so as to concurrently optimize the CFRC curved thin-walled structures. Notably, key innovations include: (1) A tangent mapping transformation mechanism between physical space and parameter space is proposed for accurate fiber orientation calculation; (2) A resampling-based symmetry technique is presented to reduce optimization variable dimensionality while avoiding suboptimal local minima. Three 3D cases (cylinder, hemisphere, and tee-branch pipe) validated the efficiency of the proposed framework in handling curved thin-walled composites with complex geometries. This work pioneers a new pathway for optimizing 3D CFRC curved thin-walled structures, which is significant for engineering structural innovation.