Freeform surfaces are popular in architectural design for their expressive aesthetics, yet they remain challenging to fabricate. A common strategy is to approximate them with assemblies of planar polygonal panels in a process we term panelization, enabling cost-effective fabrication from sheet materials such as wood, metal, or glass. Our goal is to compute panelizations that are both geometrically faithful and structurally robust. A two-stage pipeline, i.e. geometric panelization followed by structural optimization, can be effective, but joint optimization may yield better outcomes by letting mechanics influence the panelization itself. The challenges are that the panelization task is inherently combinatorial, and structural objectives depend on stresses that have a complex, global dependence on the geometry and are costly to evaluate. Moreover, improving structural performance must be balanced against preserving the input surface's design intent. To address these challenges, we formulate panelization as a continuous surface flow coupled to stress analysis, by modeling candidates as creased elastic shells. We define a global objective by integrating an arbitrary function of stress over the shell and derive efficient gradients with respect to the surface shape to enable optimization. We further introduce flow terms that better preserve the input shape and show that running BFGS in a Sobolev space substantially outperforms standard BFGS and Sobolev gradient descent. We evaluate our method on architectural models, showing that incorporating stress during panelization yields substantial stress reductions and more robust designs compared to optimizing stress after fixing the panelization.

We introduce a high-performance framework for solving nonconvex optimization problems arising in simulation and geometry processing applications. Our framework especially benefits high-dimensional problems whose unknowns are spatial coordinates in ℝ d and whose objectives are expressed as a sum of element energies over small stencils. The Hessians of these problems have a block-sparse structure, where the nonzero entries are grouped into dense d × d blocks. Many works have exploited this structure to speed up the Hessian-vector products and nodal smoothers of iterative solvers. In contrast, accelerating direct sparse linear solvers, preferred for applications requiring high accuracy on unstructured grids, has been less explored. Our framework leverages block structure to accelerate all phases of a Newton-type minimization algorithm, from sparsity pattern construction to system assembly, matrix factorization, and solves. A fundamental piece of the framework is BlockCatamari, our highly tuned, block-accelerated multifrontal sparse Cholesky code that achieves significantly faster factorizations than existing direct solvers on shared-memory systems. We combine this solver with our fast parallel Hessian assembly routine, heuristics for conditionally enabling per-element Hessian projections, and strategies for minimizing symbolic factorization re-computations. We show that this leads to dramatic speedups on a large suite of benchmark problems involving injective surface parametrization and elasticity simulation with contact, and we further demonstrate the ease with which new energies can be defined at the different levels of abstraction offered by our framework.

We introduce a neural-preconditioned iterative solver for Poisson equations with mixed boundary conditions. Typical Poisson discretizations yield large, ill-conditioned linear systems. Iterative solvers can be effective for these problems, but only when equipped with powerful preconditioners. Unfortunately, effective preconditioners like multigrid require costly setup phases that must be re-executed every time domain shapes or boundary conditions change, forming a severe bottleneck for problems with evolving boundaries. In contrast, we present a neural preconditioner trained to efficiently approximate the inverse of the discrete Laplacian in the presence of such changes. Our approach generalizes to domain shapes, boundary conditions, and grid sizes outside the training set. The key to our preconditioner's success is a novel, lightweight neural network architecture featuring spatially varying convolution kernels and supporting fast inference. We demonstrate that our solver outperforms state-of-the-art methods like algebraic multigrid as well as recently proposed neural preconditioners on challenging test cases arising from incompressible fluid simulations.

Surface-based inflatables are composed of two thin layers of nearly inextensible sheet material joined together along carefully selected fusing curves. During inflation, pressure forces separate the two sheets to maximize the enclosed volume. The fusing curves restrict this expansion, leading to a spatially varying in-plane contraction and hence metric frustration. The inflated structure settles into a 3D equilibrium that balances pressure forces with the internal elastic forces of the sheets. We present a computational framework for analyzing and designing surface-based inflatable structures with arbitrary fusing patterns. Our approach employs numerical homogenization to characterize the behavior of parametric families of periodic inflatable patch geometries, which can then be combined to tessellate the sheet with smoothly varying patterns. We propose a novel parametrization of the underlying deformation space that allows accurate, efficient, and systematical analysis of the stretching and bending behavior of inflated patches with potentially open boundaries. We apply our homogenization algorithm to create a database of geometrically diverse fusing patterns spanning a wide range of material properties and deformation characteristics. This database is employed in an inverse design algorithm that solves for fusing curves to best approximate a given input target surface. Local patches are selected and blended to form a global network of curves based on a geometric flattening algorithm. These fusing curves are then further optimized to minimize the distance of the deployed structure to target surface. We show that this approach offers greater flexibility to approximate given target geometries compared to previous work while significantly improving structural performance.

We introduce a computational pipeline for simulating and designing C-shells , a new class of planar-to-spatial deployable linkage structures. A C-shell is composed of curved flexible beams connected at rotational joints that can be assembled in a stress-free planar configuration. When actuated, the elastic beams deform and the assembly deploys towards the target 3D shape. We propose two alternative computational design approaches for C-shells: (i) Forward exploration simulates the deployed shape from a planar beam layout provided by the user. Once a satisfactory overall shape is found, a subsequent design optimization adapts the beam geometry to reduce the elastic energy of the linkage while preserving the target shape. (ii) Inverse design is facilitated by a new geometric flattening method that takes a design surface as input and computes an initial layout of piecewise straight linkage beams. Our design optimization algorithm then calculates the smooth curved beams to best reproduce the target shape at minimal elastic energy. We find that C-shells offer a rich space for design and show several studies that highlight new shape topologies that cannot be achieved with existing deployable linkage structures.

We present an algorithmic approach to discover, study, and design multistable elastic knots. Elastic knots are physical realizations of closed curves embedded in 3-space. When endowed with the material thickness and bending resistance of a physical wire, these knots settle into equilibrium states that balance the forces induced by elastic deformation and self-contacts of the wire. In general, elastic knots can have many distinct equilibrium states, i.e. they are multistable mechanical systems. We propose a computational pipeline that combines randomized spatial sampling and physics simulation to efficiently find stable equilibrium states of elastic knots. Leveraging results from knot theory, we run our pipeline on thousands of different topological knot types to create an extensive data set of multistable knots. By applying a series of filters to this data, we discover new transformable knots with interesting geometric and physical properties. A further analysis across knot types reveals geometric and topological patterns, yielding constructive principles that generalize beyond the currently tabulated knot types. We show how multistable elastic knots can be used to design novel deployable structures and engaging recreational puzzles. Several physical prototypes at different scales highlight these applications and validate our simulation.

Mechanical metamaterials enable customizing the elastic properties of physical objects by altering their fine-scale structure. A broad gamut of effective material properties can be produced even from a single fabrication material by optimizing the geometry of a periodic microstructure tiling. Past work has extensively studied the capabilities of microstructures in the small-displacement regime, where periodic homogenization of linear elasticity yields computationally efficient optimal design algorithms. However, many applications involve flexible structures undergoing large deformations for which the accuracy of linear elasticity rapidly deteriorates due to geometric nonlinearities. Design of microstructures at finite strains involves a massive increase in computation and is much less explored; no computational tool yet exists to design metamaterials emulating target hyperelastic laws over finite regions of strain space. We make an initial step in this direction, developing algorithms to accelerate homogenization and metamaterial design for nonlinear elasticity and building a complete framework for the optimal design of planar metamaterials. Our nonlinear homogenization method works by efficiently constructing an accurate interpolant of a microstructure's deformation over a finite space of macroscopic strains likely to be endured by the metamaterial. From this interpolant, the homogenized energy density, stress, and tangent elasticity tensor describing the microstructure's effective properties can be inexpensively computed at any strain. Our design tool then fits the effective material properties to a target constitutive law over a region of strain space using a parametric shape optimization approach, producing a directly manufacturable geometry. We systematically test our framework by designing a catalog of materials fitting isotropic Hooke's laws as closely as possible. We demonstrate significantly improved accuracy over traditional linear metamaterial design techniques by fabricating and testing physical prototypes.

Objects with different shapes can dissolve in significantly different ways inside a solution. Predicting different shapes' dissolution dynamics is an important problem especially in pharmaceutics. More important and challenging, however, is controlling the dissolution via shape, i.e. , designing shapes that lead to a desired release behavior of materials in a solvent over a specific time. Here, we tackle this challenge by introducing a computational inverse design pipeline. We begin by introducing a simple, physically-inspired differentiable forward model of dissolution. We then formulate our inverse design as a PDE-constrained topology optimization that has access to analytical derivatives obtained via sensitivity analysis. Furthermore, we incorporate fabricability terms in the optimization objective that enable physically realizing our designs. We thoroughly analyze our approach on a diverse set of examples via both simulation and fabrication.

We present a computational inverse design framework for a new class of volumetric deployable structures that have compact rest states and deploy into bending-active 3D target surfaces. Umbrella meshes consist of elastic beams, rigid plates, and hinge joints that can be directly printed or assembled in a zero-energy fabrication state. During deployment, as the elastic beams of varying heights rotate from vertical to horizontal configurations, the entire structure transforms from a compact block into a target curved surface. Umbrella Meshes encode both intrinsic and extrinsic curvature of the target surface and in principle are free from the area expansion ratio bounds of past auxetic material systems. We build a reduced physics-based simulation framework to accurately and efficiently model the complex interaction between the elastically deforming components. To determine the mesh topology and optimal shape parameters for approximating a given target surface, we propose an inverse design optimization algorithm initialized with conformal flattening. Our algorithm minimizes the structure's strain energy in its deployed state and optimizes actuation forces so that the final deployed structure is in stable equilibrium close to the desired surface with few or no external constraints. We validate our approach by fabricating a series of physical models at various scales using different manufacturing techniques.

We present Bistable Auxetic Surface Structures , a novel deployable material system based on optimized bistable auxetic cells. Such a structure can be flat-fabricated from elastic sheet material, then deployed towards a desired double-curved target shape by activating the bistable mechanism of its component cells. A unique feature is that the deployed model is by design in a stable state. This facilitates deployment without the need of complex external supports or boundary constraints. We introduce a computational solution for the inverse design of our Bistable Auxetic Surface Structures. Our algorithm first precomputes a library of bistable auxetic cells to cover a range of in-plane expansion / contraction ratios, while maximizing the bistability and stiffness of the cell to ensure robust deployment. We then use metric distortion analysis of the target surface to compute the planar fabrication state as a composition of cells that best matches the desired deployment deformation. As each cell expands or contracts during deployment, metric frustration forces the surface towards its target equilibrium state. We validate our method with several physical prototypes.

We present a computational inverse design method for a new class of surface-based inflatable structure. Our deployable structures are fabricated by fusing together two layers of inextensible sheet material along carefully selected curves. The fusing curves form a network of tubular channels that can be inflated with air or other fluids. When fully inflated, the initially flat surface assumes a programmed double-curved shape and becomes stiff and load-bearing. We present a method that solves for the layout of air channels that, when inflated, best approximate a given input design. For this purpose, we integrate a forward simulation method for inflation with a gradient-based optimization algorithm that continuously adapts the geometry of the air channels to improve the design objectives. To initialize this non-linear optimization, we propose a novel surface flattening algorithm. When a channel is inflated, it approximately maintains its length, but contracts transversally to its main direction. Our algorithm approximates this deformation behavior by computing a mapping from the 3D design surface to the plane that allows for anisotropic metric scaling within the bounds realizable by the physical system. We show a wide variety of inflatable designs and fabricate several prototypes to validate our approach and highlight potential applications.

Basket weaving is a traditional craft for creating curved surfaces as an interwoven array of thin, flexible, and initially straight ribbons. The three-dimensional shape of a woven structure emerges through a complex interplay of the elastic bending behavior of the ribbons and the contact forces at their crossings. Curvature can be injected by carefully placing topological singularities in the otherwise regular weaving pattern. However, shape control through topology is highly non-trivial and inherently discrete, which severely limits the range of attainable woven geometries. Here, we demonstrate how to construct arbitrary smooth free-form surface geometries by weaving carefully optimized curved ribbons. We present an optimization-based approach to solving the inverse design problem for such woven structures. Our algorithm computes the ribbons' planar geometry such that their interwoven assembly closely approximates a given target design surface in equilibrium. We systematically validate our approach through a series of physical prototypes to show a broad range of new woven geometries that is not achievable by existing methods. We anticipate our computational approach to significantly enhance the capabilities for the design of new woven structures. Facilitated by modern digital fabrication technology, we see potential applications in material science, bio- and mechanical engineering, art, design, and architecture.

New fabrication technologies have significantly decreased the cost of fabrication of shapes with highly complex geometric structure. One important application of complex fine-scale geometric structures is to create variable effective elastic material properties in shapes manufactured from a single material. Modification of material properties has a variety of uses, from aerospace applications to soft robotics and prosthetic devices. Due to its scalability and effectiveness, an increasingly common approach to creating spatially varying materials is to partition a shape into cells and use a parametric family of small-scale geometric structures with known effective properties to fill the cells. We propose a new approach to solving this problem for extruded, planar microstructures. Differently from existing methods for two-scale optimization based on regular grids with square periodic cells, which cannot conform to an arbitrary boundary, we introduce cell decompositions consisting of (nearly) rhombic cells. These meshes have far greater flexibility than those with square cells in terms of approximating arbitrary shapes, and, at the same time, have a number of properties simplifying small-scale structure construction. Our main contributions include a new family of 2D cell geometry structures, explicitly parameterized by their effective Young's moduli E , Poisson's ratios v , and rhombic angle α with the geometry parameters expressed directly as smooth spline functions of E, v , and α. This family leads to smooth transitions between the tiles and can handle a broad range of rhombic cell shapes. We introduce a complete material design pipeline based on this microstructure family, composed of an algorithm to generate rhombic tessellation from quadrilateral meshes and an algorithm to synthesize the microstructure geometry. We fabricated a number of models and experimentally demonstrated how our method, in combination with material optimization, can be used to achieve the desired deformation behavior.

We present X-shells , a new class of deployable structures formed by an ensemble of elastically deforming beams coupled through rotational joints. An X-shell can be assembled conveniently in a flat configuration from standard elastic beam elements and then deployed through force actuation into the desired 3D target state. During deployment, the coupling imposed by the joints will force the beams to twist and buckle out of plane to maintain a state of static equilibrium. This complex interaction of discrete joints and continuously deforming beams allows interesting 3D forms to emerge. Simulating X-shells is challenging, however, due to unstable equilibria at the onset of beam buckling. We propose an optimization-based simulation framework building on a discrete rod model that robustly handles such difficult scenarios by analyzing and appropriately modifying the elastic energy Hessian. This real-time simulation method forms the basis of a computational design tool for X-shells that enables interactive design space exploration by varying and optimizing design parameters to achieve a specific design intent. We jointly optimize the assembly state and the deployed configuration to ensure the geometric and structural integrity of the deployable X-shell. Once a design is finalized, we also optimize for a sparse distribution of actuation forces to efficiently deploy it from its flat assembly state to its 3D target state. We demonstrate the effectiveness of our design approach with a number of design studies that highlight the richness of the X-shell design space, enabling new forms not possible with existing approaches. We validate our computational model with several physical prototypes that show excellent agreement with the optimized digital models.

Deployable structures are physical mechanisms that can easily transition between two or more geometric configurations; such structures enable industrial, scientific, and consumer applications at a wide variety of scales. This paper develops novel deployable structures that can approximate a large class of doubly-curved surfaces and are easily actuated from a flat initial state via inflation or gravitational loading. The structures are based on two-dimensional rigid mechanical linkages that implicitly encode the curvature of the target shape via a user-programmable pattern that permits locally isotropic scaling under load. We explicitly characterize the shapes that can be realized by such structures---in particular, we show that they can approximate target surfaces of positive mean curvature and bounded scale distortion relative to a given reference domain. Based on this observation, we develop efficient computational design algorithms for approximating a given input geometry. The resulting designs can be rapidly manufactured via digital fabrication technologies such as laser cutting, CNC milling, or 3D printing. We validate our approach through a series of physical prototypes and present several application case studies, ranging from surgical implants to large-scale deployable architecture.

Additive fabrication technologies are limited by the types of material they can print: while the technologies are continuously improving, still only a relatively small discrete set of materials can be used in each printed object. At the same time, the low cost of introducing geometric complexity suggests the alternative of controlling the elastic material properties by producingmicrostructures, which can achieve behaviors significantly differing from the solid printing material. While promising results have been obtained in this direction, fragility is a significant problem blocking practical applications, especially for achieving soft material properties: due to stress concentrations at thin joints, deformations and repeated loadings are likely to cause fracture. We present a set of methods to minimize stress concentrations in microstructures by evolving their shapes. First, we demonstrate that the worst-case stress analysis problem (maximizing a stress measure over all possible unit loads) has an exact solution for periodic microstructures. We develop a new, accurate discretization of the shape derivative for stress objectives and introduce a low-dimensional parametric shape model for microstructures. This model supports robust minimization of maximal stress (approximated by anLpnorm with highp) and an efficient implementation of printability constraints. In addition to significantly reducing stresses (by a typical factor of 5X), the new method substantially expands the range of effective material properties covered by the collection of structures.

We introduce elastic textures: a set of parametric, tileable, printable, cubic patterns achieving a broad range of isotropic elastic material properties: the softest pattern is over a thousand times softer than the stiffest, and the Poisson's ratios range from below zero to nearly 0.5. Using a combinatorial search over topologies followed by shape optimization, we explore a wide space of truss-like, symmetric 3D patterns to obtain a small family. This pattern family can be printed without internal support structure on a single-material 3D printer and can be used to fabricate objects with prescribed mechanical behavior. The family can be extended easily to create anisotropic patterns with target orthotropic properties. We demonstrate that our elastic textures are able to achieve a user-supplied varying material property distribution. We also present a material optimization algorithm to choose material properties at each point within an object to best fit a target deformation under a prescribed scenario. We show that, by fabricating these spatially varying materials with elastic textures, the desired behavior is achieved.

Direct digital manufacturing is a set of rapidly evolving technologies that provide easy ways to manufacture highly customized and unique products. The development pipeline for such products is radically different from the conventional manufacturing pipeline: 3D geometric models are designed by users often with little or no manufacturing experience, and sent directly to the printer. Structural analysis on the user side with conventional tools is often unfeasible as it requires specialized training and software. Trial-and-error, the most common approach, is time-consuming and expensive. We present a method that would identify structural problems in objects designed for 3D printing based on geometry and material properties only , without specific assumptions on loads and manual load setup. We solve a constrained optimization problem to determine the "worst" load distribution for a shape that will cause high local stress or large deformations. While in its general form this optimization has a prohibitively high computational cost, we demonstrate that an approximate method makes it possible to solve the problem rapidly for a broad range of printed models. We validate our method both computationally and experimentally and demonstrate that it has good predictive power for a number of diverse 3D printed shapes.

Given the large volume of images being sent back from remote spacecraft, there is a need for automated analysis techniques that can quickly identify interesting features in those images. Feature identification in individual images and automated change detection in multiple images of the same target are valuable for scientific studies and can inform subsequent target selection. We introduce a new approach to orbital image analysis called dynamic landmarking. It focuses on the identification and comparison of visually salient features in images. We have evaluated this approach on images collected by five Mars orbiters. These evaluations were motivated by three scientific goals: to study fresh impact craters, dust devil tracks, and dark slope streaks on Mars. In the process we also detected a different kind of surface change that may indicate seasonally exposed bedforms. These experiences also point the way to how this approach could be used in an onboard setting to analyze and prioritize data as it is collected.