The honeycomb based discretization shows promise in yielding checkerboard and point flexure free optimal solutions to various topology design problems. The mesh-free material mask overlay method further promises unadulterated “black and white” optimal solutions as opposed to schemes where material is interpolated between the “void” and “filled” states in a cell [26]. Here, we propose improvements in the material mask overlay method by judiciously choosing the number of masks during a sequence of sub-searches for the optimal solution. We use an alternative mutation based zero order search which allows the use of a small population of solutions and also maintains diversity between them. Thus, multiple solutions can be simultaneously obtained for non-convex topology optimization formulations. We solve two classical problems each on optimal stiff structures and compliant mechanisms to illustrate pathology free, “black and white” topology synthesis.

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