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In this paper we report a new promising idea on the design and manufacturingof ply composite structures, tailored to exhibit maximum stiffness under givenweight constraints and loading conditions. It is based on the idea behind anartistic technique known as "string art" - the representation of an image witha single thread, tensioned between pins on the flat frame. A discreteoptimization algorithm has been employed recently to formalize the process offinding a configuration of thread windings that fuses into a given greyscaleimage. We demonstrate how this algorithm can be employed to approximate thetwo-dimensional distribution of isotropic material, computed by a conventionaltopology optimization algorithm. An optimal composite design is thus found as aresult of the following two-stage process. At the first stage, topologyoptimization procedure produces regular grid of greyscale values of stiffness.At the second stage, this distribution is approximated with a polyline,representing the stiff reinforcement fiber in a soft matrix, according to``string art'' optimization algorithm. The efficiency of the proposed approachis illustrated with few simple numerical examples. Our development opens a wideavenue for the industrial design of the new generation of fibrous compositestructures.

A "String Art" approach to the design and manufacturing of optimal composite materials and structures