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In this article, a novel explicit approach for designing complex thin-walledstructures based on the Moving Morphable Component (MMC) method is proposed,which provides a unified framework to systematically address various designissues, including topology optimization, reinforced-rib layout optimization,and sandwich structure design problems. The complexity of thin-walledstructures mainly comes from flexible geometries and the variation ofthickness. On the one hand, the geometric complexity of thin-walled structuresleads to the difficulty in automatically describing material distribution(e.g., reinforced ribs). On the other hand, thin-walled structures withdifferent thicknesses require various hypotheses (e.g., Kirchhoff-Love shelltheory and Reissner-Mindlin shell theory) to ensure the precision of structuralresponses. Whereas for cases that do not fit the shell hypothesis, theprecision loss of response solutions is nonnegligible in the optimizationprocess since the accumulation of errors will cause entirely different designs.Hence, the current article proposes a novel embedded solid component to tacklethese challenges. The geometric constraints that make the components fit to thecurved thin-walled structure are whereby satisfied. Compared with traditionalstrategies, the proposed method is free from the limit of shell assumptions ofstructural analysis and can achieve optimized designs with clear loadtransmission paths at the cost of few design variables and degrees of freedomfor finite element analysis (FEA). Finally, we apply the proposed method toseveral representative examples to demonstrate its effectiveness, efficiency,versatility, and potential to handle complex industrial structures.

A novel explicit design method for complex thin-walled structures based on embedded solid moving morphable components