Co-Optimization of Structure and Manufacturable Semi-Continuous Layers for Laminated Composites

To enable the design and manufacturing of optimized composite structures using fabric plies, we propose a field-driven optimization framework that jointly optimizes structural topology and manufacturable layers. A central challenge in this setting is the modeling and optimization of partial fabric layers with near-uniform thickness, which we formulate as a semi-continuous periodic scalar field parameterized by a continuous implicit neural vector field. Within this concurrent structure-layer optimization framework, we further derive a formulation of inter-layer anisotropic mechanical behavior that enables effective modeling of mechanical property transitions induced by partial-layer boundaries, together with additional objectives for manufacturability and field regularization. We validate the effectiveness of our approach through both numerical simulations and physical experiments, demonstrating that the optimized fabric-reinforced laminated composites achieve up to 43.8% higher stiffness compared to counterparts fabricated using planar fabric plies.