Abstract Maintaining the maximum stiffness of components with as little material as possible is an overarching objective in computational design and engineering. It is well‐established that in stiffness‐optimal designs, material is aligned with orthogonal principal stress directions. In the limit of material volume, this alignment forms micro‐structures resembling quads or hexahedra. Achieving a globally consistent layout of such orthogonal micro‐structures presents a significant challenge, particularly in three‐dimensional settings. In this paper, we propose a novel geometric algorithm for compiling stress‐aligned hexahedral lattice structures. Our method involves deforming an input mesh under load to align the resulting stress field along an orthogonal basis. The deformed object is filled with a hexahedral grid, and the deformation is reverted to recover the original shape. The resulting stress‐aligned mesh is used as basis for a final hollowing procedure, generating a volume‐reduced stiff infill composed of hexahedral micro‐structures. We perform quantitative comparisons with structural optimization and hexahedral meshing approaches and demonstrate the superior mechanical performance of our designs with finite element simulation experiments.

We introduce the Stress-Guided Lightweight Design Benchmark (SGLDBench), a comprehensive benchmark suite for applying and evaluating material layout strategies to generate stiff, lightweight designs in 3D domains. SGLDBench provides a seamlessly integrated simulation and analysis framework, including six reference strategies and a scalable multigrid elasticity solver to efficiently execute these strategies and validate the stiffness of their results. This facilitates the systematic analysis and comparison of design strategies based on the mechanical properties they achieve. SGLDBench enables the evaluation of diverse load conditions and, through the tight integration of the solver, supports high-resolution designs and stiffness analysis. Additionally, SGLDBench emphasizes visual analysis to explore the relationship between the geometric structure of a design and the distribution of stresses, offering insights into the specific properties and behaviors of different design strategies. SGLDBench's specific features are highlighted through several experiments, comparing the results of reference strategies with respect to geometric and mechanical properties.

The visual inspection of a hexahedral mesh with respect to element quality is difficult due to clutter and occlusions that are produced when rendering all element faces or their edges simultaneously. Current approaches overcome this problem by using focus on specific elements that are then rendered opaque, and carving away all elements occluding their view. In this work, we make use of advanced GPU shader functionality to generate a focus+context rendering that highlights the elements in a selected region and simultaneously conveys the global mesh structure and deformation field. To achieve this, we propose a gradual transition from edge-based focus rendering to volumetric context rendering, by combining fragment shader-based edge and face rendering with per-pixel fragment lists. A fragment shader smoothly transitions between wireframe and face-based rendering, including focus-dependent rendering style and depth-dependent edge thickness and halos, and per-pixel fragment lists are used to blend fragments in correct visibility order. To maintain the global mesh structure in the context regions, we propose a new method to construct a sheet-based level-of-detail hierarchy and smoothly blend it with volumetric information. The user guides the exploration process by moving a lens-like hotspot. Since all operations are performed on the GPU, interactive frame rates are achieved even for large meshes.

Abstract We present a visualization technique for 2D stress tensor fields based on the construction of a globally conforming lattice. Conformity ensures that the lattice edges follow the principal stress directions and the aspect ratio of lattice elements represents the stress anisotropy. Since such a lattice structure cannot be space‐filling in general, it is constructed from multiple intersecting lattice beams. Conformity at beam intersections is ensured via a constrained optimization problem, by computing the aspect ratio of elements at intersections so that their edges meet when continued along the principal stress lines. In combination with a coloring scheme that encodes relative stress magnitudes, a global visualization is achieved. By introducing additional constraints on the positional variation of the beam intersections, coherent visualizations are achieved when external loads or material parameters are changed. In a number of experiments using non‐trivial scenarios, we demonstrate the capability of the proposed visualization technique to show the global and local structure of a given stress field.