Process simulation-informed topology optimization for formwork-based concrete casting

Abstract Concrete casting, a cornerstone of construction, relies on formwork to shape structures and has been used to create topology-optimized lightweight designs. The interplay between cast structures and formwork necessitates balancing casting constraints, particularly filling efficiency in topological channels, to avoid defects that compromise performance. However, filling efficiency is often empirically addressed, limiting optimization potential. Traditional methods require extensive post-processing to improve filling efficiency, increasing costs and design time. This work introduces a process simulation-informed reverse topology optimization framework, integrating casting constraints into the design process. The framework combines topology optimization, Discrete Element Method (DEM) simulation, and filling ratio identification. Its effectiveness is demonstrated through 2D numerical examples, experimental validation, and a preliminary 3D extension. Results show that the optimized structures improve filling efficiency and allow customizable casting positions. This approach offers a novel strategy for formwork optimization, enhancing efficiency and reducing costs in the building industry.