This paper presents a configuration and sizing design optimization method for large deformation compliant mechanisms, using a continuum-based adjoint design sensitivity analysis (DSA) approach for built-up structures. Under the total Lagrangian formulation, the Jaumann strain formulation using the discretization of global displacement field is employed, to account for the finite deformation of arbitrarily curved Kirchhoff beams. In multi-patch models, the rotation continuity condition at junctions is imposed using penalty and Lagrange multiplier methods. The developed adjoint DSA method can handle non-conservative loading conditions, which lead to asymmetry of tangent operator. Performance measures are displacements and rotation angles, and neutral axis configurations and cross-section thicknesses are considered as design variables. Also, analytical design sensitivity expressions for the rotation continuity condition are derived. Various compliant mechanisms, including path-generators under deformation-dependent loadings, are synthesized to demonstrate the applicability of the proposed method.

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