Molding direction constraints in structural optimization via a level-set method

In the framework of structural optimization via a level-set method, we develop an approach to handle the directional molding constraint for cast parts. A novel molding condition is formulated and a penalization method is used to enforce the constraint. A first advantage of our new approach is that it does not require to start from a feasible initialization, but it guarantees the convergence to a castable shape. A second advantage is that our approach can incorporate thickness constraints too. We do not address the optimization of the casting system, which is considered a priori defined. We show several 3d examples of compliance minimization in linearized elasticity under molding and minimal or maximal thickness constraints. We also compare our results with formulations already existing in the literature.