Topology Optimization of Composite Self-Deployable Thin Shells with Cutouts

The paper presents topology optimization studies of selfs-deployable joints in thin-walled tubular structures. The joints are made entirely of ultra-thin, fiber reinforced composite materials. The objective of this research is to strategically position cutouts on the joints so that they can fold without failing, while maximizing the deployed bending stiffness. The optimal shape and position of cutouts are the results of concurrent topology optimization of these composite, thin-shell joints with geometrical non-linearities, due to their folding and self-deployable nature. Numerical methods to accurately detect failure are implemented and results from a novel level-set method for topology optimization are compared to results from classical parametric optimization and preliminary designs based on physical intuition.