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A multi-domain and multi-step topology optimization approach is presented in this paper, which can be used to simplify the architecture/topological structure of an “optimum” structure obtained from the topology optimization process, and thus significantly improves the manufacturability of the final design. Examples will be given to illustrate how this approach can be applied to a realistic engineering design problem for developing lightweight and high-performance structures in next-generation ground vehicles.

The objective of this research is to verify the optimum design obtained from a topology optimization process. The verification is through both numerical analysis and physical test. It will be shown that the optimum topology obtained from an example topology optimization process is independent of the material used and the dimension/size of the structure. This important feature is then proved for more general cases through theoretical analyses, numerical simulations, and physical experiments. The result extends the applicability of the optimum design and simplifies the prototyping and test process thus will result in significant cost saving in building full-size prototypes and performing expensive tests. This work is a combined effort with theoretical, numerical and experimental methods. A multi-domain multi-step topology optimization technique [1] will be utilized to find the optimum structural design.