Design Optimization of Fiber‐Reinforced Structures With Intervening a Manufacturing Constraint

ABSTRACT Efficient fiber path planning plays a crucial role in enhancing the mechanical properties of composites. Leveraging level‐set methods and mesh dynamic representation (MDR), this study introduces a novel approach for generating and optimizing fiber paths. Initially, a reference fiber orientation is defined on a mesh, and networked fibers within each ply are represented using level sets, thereby establishing the fiber paths. The proposed method is then applied to solve an optimization problem—specifically, a minimum flexibility problem—where the structure is iteratively modified to achieve maximum stiffness under given constraints. Key design variables are formulated to govern the location and geometry of the initial path, and visual representations of the design space are analyzed to identify both localized and global optima. Furthermore, the optimization challenge incorporating curvature constraints is addressed, demonstrating the validity of the proposed methodology. All computational algorithms developed in this study are implemented using commercial software tools, ensuring practical applicability and scalability.