Binary-Coerced Multiphysics Topology Optimization for Manufacturable Dielectric Metamaterials

Abstract

Inverse-designed dielectric metadevices generated through adjoint and topology optimization methods frequently exhibit continuous material distributions that are difficult to fabricate and structurally validate. This work presents a fabrication-oriented multiphysics topology optimization framework that systematically converts continuous electromagnetic designs into manufacturable solid dielectric metastructures while preserving gradient-driven convergence. The approach integrates electromagnetic adjoint sensitivities with mechanical SIMP-based gradients inside a unified optimization loop and introduces a converging binary coercion operation that drives material densities toward discrete states without destroying gradient fidelity. The method is geometry-agnostic and applicable across a broad class of metamaterial devices. Demonstrations on dielectric meta-structures show simultaneous electromagnetic gain enhancement and structural robustness under load, illustrating a practical pathway from inverse-designed metamaterial fields to additively manufacturable dielectric components.