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This paper presents a general and reliable shape optimization scheme for snap-through structures to match a target load-deflection curve. The simulation of the snap-through structures typically requires the Arc Length Control (ALC) method. The adaptive stepping in ALC creates unavoidable discontinuities in the objective function. A discontinuous objective function is often handled by zero-order methods. However, we opt to solve the optimization problems using gradient-only optimization. Numerical examples demonstrate that function value based methods can misinterpret discontinuities as minima and terminate prematurely. In contrast, gradient-only algorithms are demonstrated to be insensitive to numerical discontinuities, and locate the correct solutions reliably.

Challenges and solutions to arc-length controlled structural shape design problems