Design of multimaterial compliant mechanisms using level-set methods

A monolithic compliant mechanism transmits applied forces from specified input ports to output ports by elastic deformation of its comprising materials, fulfilling required functions analogous to a rigid-body mechanism. In this paper, we propose a level-set method for designing monolithic compliant mechanisms made of multiple materials as an optimization of continuum heterogeneous structures. Central to the method is a multiphase level-set model that precisely specifies the distinct material regions and their sharp interfaces as well as the geometric boundary of the structure. Combined with the classical shape derivatives, the level-set method yields an Eulerian computational system of geometric partial differential equations, capable of performing topological changes and capturing geometric evolutions at the interface and the boundary. The proposed method is demonstrated for single-input and single-output mechanisms and illustrated with several two-dimensional examples of synthesis of multimaterial mechanisms of force inverters and gripping and clamping devices. An analysis on the formation of de facto hinges is presented based on the shape gradient information. A scheme to ensure a well-connected topology of the mechanism during the process of optimization is also presented.