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This paper presents a hybrid level set method (HLSM) to design novelty functionally graded structures (FGSs) with complex macroscopic graded patterns. The hybrid level set function (HLSF) is constructed to parametrically model the macro unit cells by introducing the affine concept of convex optimization theory. The global weight coefficients on macro unit cell nodes and the local weight coefficients within the macro unit cell are defined as master and slave design variables, respectively. The local design variables are interpolated by the global design variables to guarantee the C 0 continuity of neighboring unit cells. A HLSM-based topology optimization model for the FGSs is established to maximize structural stiffness. The optimization model is solved by the optimality criteria (OC) algorithm. Two typical FGSs design problems are investigated, including thin-walled stiffened structures (TWSSs) and functionally graded cellular structures (FGCSs). In addition, additively manufactured FGCSs with different core layers are tested for bending performance. Numerical examples show that the HLSM is effective for designing FGSs like TWSSs and FGCSs. The bending tests prove that FGSs designed using HLSM are have a high performance.

A Hybrid Level Set Method for the Topology Optimization of Functionally Graded Structures