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This study presents a topological optimization method for flexure hinges based on explicit geometric representation, precisely characterizing material boundaries and load-transfer paths through parameterized wide Bézier components. Numerical examples establish geometrically generic optimized configurations by constraining Bézier component boundaries and applying symmetry constraints, systematically investigating the effects of material volume fraction  \(V^*\) (15%–30%), number of components  \(M\) , and number of control points  \(p\) on topological outcomes. Results show that optimization results under different  \(V^*\) all exhibit cross-type compliant hinge topologies, with volume fraction only altering material distribution density without significantly affecting the basic topological morphology, verifying the method’s effectiveness and robustness. For  \(M\) and  \(p\) , although cross-type hinges are generated at all values, increasing their magnitudes significantly enhances optimization degrees of freedom, leading to localized structural complexity—more control points tend to form “necking” features that induce stress concentration, while more components introduce small-holes affecting manufacturability. In conclusion, this method provides a new paradigm for flexure hinge design, though its “necking” and small-porous structures require further optimization in future research to enhance engineering applicability.

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Design of Flexure Hinge Based on Explicit Structural Topology Optimization

  • 会议论文

  • 发表日期：

    2026年

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  • Jierong Li,
  • Benliang Zhu,
  • Zhenfeng Wu,
  • Yang Shen,
  • Andrés Kecskeméthy,
  • Xianmin Zhang

摘要

This study presents a topological optimization method for flexure hinges based on explicit geometric representation, precisely characterizing material boundaries and load-transfer paths through parameterized wide Bézier components. Numerical examples establish geometrically generic optimized configurations by constraining Bézier component boundaries and applying symmetry constraints, systematically investigating the effects of material volume fraction  \(V^*\) (15%–30%), number of components  \(M\) , and number of control points  \(p\) on topological outcomes. Results show that optimization results under different  \(V^*\) all exhibit cross-type compliant hinge topologies, with volume fraction only altering material distribution density without significantly affecting the basic topological morphology, verifying the method’s effectiveness and robustness. For  \(M\) and  \(p\) , although cross-type hinges are generated at all values, increasing their magnitudes significantly enhances optimization degrees of freedom, leading to localized structural complexity—more control points tend to form “necking” features that induce stress concentration, while more components introduce small-holes affecting manufacturability. In conclusion, this method provides a new paradigm for flexure hinge design, though its “necking” and small-porous structures require further optimization in future research to enhance engineering applicability.