For robot manipulation, both the controller and end-effector design are crucial. Soft grippers are generalizable by deforming to different geometries, but designing such a gripper and finding its grasp pose remains challenging. In this paper, we propose a co-design framework that generates an optimized soft gripper's block-wise stiffness distribution and its grasping pose, using a neural physics model trained in simulation. We derived a uniform-pressure tendon model for a flexure-based soft finger, then generated a diverse dataset by randomizing both gripper pose and design parameters. A neural network is trained to approximate this forward simulation, yielding a fast, differentiable surrogate. We embed that surrogate in an end-to-end optimization loop to optimize the ideal stiffness configuration and best grasp pose. Finally, we 3D-print the optimized grippers of various stiffness by changing the structural parameters. We demonstrate that our co-designed grippers significantly outperform baseline designs in both simulation and hardware experiments. More info: http://yswhynot.github.io/codesign-soft/

We compare full-space, reduced-space, and gray-box formulations for representing trained neural networks in nonlinear constrained optimization problems. We test these formulations on a transient stability-constrained, security-constrained alternating current optimal power flow (SCOPF) problem where the transient stability criteria are represented by a trained neural network surrogate. Optimization problems are implemented in JuMP and trained neural networks are embedded using a new Julia package: MathOptAI.jl. To study the bottlenecks of the three formulations, we use neural networks with up to 590 million trained parameters. The full-space formulation is bottlenecked by the linear solver used by the optimization algorithm, while the reduced-space formulation is bottlenecked by the algebraic modeling environment and derivative computations. The gray-box formulation is the most scalable and is capable of solving with the largest neural networks tested. It is bottlenecked by evaluation of the neural network's outputs and their derivatives, which may be accelerated with a graphics processing unit (GPU). Leveraging the gray-box formulation and GPU acceleration, we solve our test problem with our largest neural network surrogate in 2.5$\times$ the time required for a simpler SCOPF problem without the stability constraint.

Robust topology optimization (RTO), as a class of topology optimization problems, identifies a design with the best average performance while reducing the response sensitivity to input uncertainties, e.g. load uncertainty. Solving RTO is computationally challenging as it requires repetitive finite element solutions for different candidate designs and different samples of random inputs. To address this challenge, a neural network method is proposed that offers computational efficiency because (1) it builds and explores a low dimensional search space which is parameterized using deterministically optimal designs corresponding to different realizations of random inputs, and (2) the probabilistic performance measure for each design candidate is predicted by a neural network surrogate. This method bypasses the numerous finite element response evaluations that are needed in the standard RTO approaches and with minimal training can produce optimal designs with better performance measures compared to those observed in the training set. Moreover, a multi-fidelity framework is incorporated to the proposed approach to further improve the computational efficiency. Numerical application of the method is shown on the robust design of L-bracket structure with single point load as well as multiple point loads.

Accurate calibration of finite element (FE) models of human intervertebral discs (IVDs) is essential for their reliability and application in diagnosing and planning treatments for spinal conditions. Traditional calibration methods are computationally intensive, requiring iterative, derivative-free optimization algorithms that often take hours or days to converge. This study addresses these challenges by introducing a novel, efficient, and effective calibration method for an L4-L5 IVD FE model using a neural network (NN) surrogate. The NN surrogate predicts simulation outcomes with high accuracy, outperforming other machine learning models, and significantly reduces the computational cost associated with traditional FE simulations. Next, a Projected Gradient Descent (PGD) approach guided by gradients of the NN surrogate is proposed to efficiently calibrate FE models. Our method explicitly enforces feasibility with a projection step, thus maintaining material bounds throughout the optimization process. The proposed method is evaluated against state-of-the-art Genetic Algorithm (GA) and inverse model baselines on synthetic and in vitro experimental datasets. Our approach demonstrates superior performance on synthetic data, achieving a Mean Absolute Error (MAE) of 0.06 compared to the baselines' MAE of 0.18 and 0.54, respectively. On experimental specimens, our method outperforms the baseline in 5 out of 6 cases. Most importantly, our approach reduces calibration time to under three seconds, compared to up to 8 days per sample required by traditional calibration. Such efficiency paves the way for applying more complex FE models, enabling accurate patient-specific simulations and advancing spinal treatment planning.

Optimal actuator and control design is studied as a multi-level optimisation problem, where the actuator design is evaluated based on the performance of the associated optimal closed loop. The evaluation of the optimal closed loop for a given actuator realisation is a computationally demanding task, for which the use of a neural network surrogate is proposed. The use of neural network surrogates to replace the lower level of the optimisation hierarchy enables the use of fast gradient-based and gradient-free consensus-based optimisation methods to determine the optimal actuator design. The effectiveness of the proposed surrogate models and optimisation methods is assessed in a test related to optimal actuator location for heat control.

We are interested in assessing the use of neural networks as surrogate models to approximate and minimize objective functions in optimization problems. While neural networks are widely used for machine learning tasks such as classification and regression, their application in solving optimization problems has been limited. Our study begins by determining the best activation function for approximating the objective functions of popular nonlinear optimization test problems, and the evidence provided shows that~SiLU has the best performance. We then analyze the accuracy of function value, gradient, and Hessian approximations for such objective functions obtained through interpolation/regression models and neural networks. When compared to interpolation/regression models, neural networks can deliver competitive zero- and first-order approximations (at a high training cost) but underperform on second-order approximation. However, it is shown that combining a neural net activation function with the natural basis for quadratic interpolation/regression can waive the necessity of including cross terms in the natural basis, leading to models with fewer parameters to determine. Lastly, we provide evidence that the performance of a state-of-the-art derivative-free optimization algorithm can hardly be improved when the gradient of an objective function is approximated using any of the surrogate models considered, including neural networks.