Adjoint-based shape optimization of a ship hull using a Conditional Variational Autoencoder (CVAE) assisted propulsion surrogate model

Accurate prediction of hydrodynamic performance is central to ship design, yet high-fidelity computational fluid dynamics remains prohibitively expensive for large-scale parametric exploration. This motivates the development of data-driven surrogate models that provide rapid approximations to hydrodynamic predictions at substantially reduced cost. We present ShipNet, a geometric deep-learning surrogate that predicts both hull-surface pressure distributions and far-field free-surface wave patterns directly from hull geometry and speed. The network employs a regularized dynamic graph convolutional backbone on hull point clouds, with a multi-head decoder for simultaneous near-body pressure and free-surface elevation outputs. Training data consist of 420 inviscid free-surface simulations generated using a potential-flow panel method for two parent yacht hulls, each parameterized into 70 variants and evaluated at three speeds. ShipNet predicts per-point pressure coefficient and two-dimensional wave elevation map using a composite loss that combines point-wise regression and image-structure terms. On a geometry-held-out test set, ShipNet achieves R^2=0.98 for hull pressure and R^2=0.91 for wave fields. Inference requires approximately 0.15s per case, yielding over a 550x speedup relative to the potential-flow solver on conventional hardware. Limitations include the restricted geometry and speed ranges and the inviscid training data, while future work will extend the model to high-fidelity viscous simulations with physics-informed regularization.

AI is increasingly used to accelerate engineering design by improving decision-making and shortening iteration cycles. Application to marine propeller design, however, remains challenging due to scarce training data and the lack of widely available pretrained models. We address this gap with a physics-based data generation pipeline and a generative-AI framework for direct performance-to-design generation tailored to marine propellers. First, we build a database of over 20,000 four- and five-bladed propeller geometries, each accompanied by simulated open-water performance curves. On top of this dataset, we develop a three-module design framework: (1) A Conditional Generation Model that proposes candidate geometries conditioned on design specifications such as target thrust, power, and diameter. (2) A Performance Prediction Model, implemented as a neural-network surrogate, that predicts thrust, torque, and efficiency in milliseconds, enabling rapid evaluation of generated designs. (3) A design refinement stage that applies evolutionary optimization to enforce practical constraints such as required thrust under power limits and bounds on blade-area ratio and thickness. Experimental results over a range of operating conditions show that the framework can generate hydrodynamically plausible propeller designs that match prescribed performance targets while substantially reducing design-iteration time relative to the traditional expert-guided refinement. Latent diffusion-based generator produces more diverse designs under the same conditions than the conditional variational autoencoder, suggesting a stronger capacity for design-space exploration with diffusion models. By coupling physics-based data synthesis with modular AI models, the proposed approach streamlines the propeller design cycle and reduces reliance on expensive high-fidelity simulations to final validation stages.

Engineering shape optimization faces challenges in both expert-dependent problem setup and surrogate-model reliability. In practical aerodynamic design, optimization settings such as editable regions, deformation ranges, and design-preservation constraints are typically specified manually by experienced engineers, while surrogate-based optimization may become unreliable for heterogeneous geometry databases and out-of-distribution designs. To address these challenges, we propose a knowledge-constrained shape-optimization framework that translates knowledge-based constraints and user intent into quantifiable parameters of DFFD-based deformation operators, enabling engineering-aware and controllable constrained optimization. We further develop a Mixture-of-Experts Neural Operator (MoE-NO) to improve drag prediction and trend consistency over heterogeneous aerodynamic datasets. Based on the MoE-NO encoder and Mahalanobis distance, an uncertainty-estimation strategy is introduced to detect out-of-distribution geometries and selectively trigger physics-solver feedback for local sample enrichment. Experiments on in-house MPV, SUV, and Sedan datasets show that MoE-NO achieves a test-set MAPE of $1.16\%$ and a trend-prediction accuracy of $94.34\%$, outperforming the best baseline results of $1.52\%$ and $90.34\%$, respectively. Vehicle shape-optimization experiments further yield CFD-validated drag coefficient reductions of approximately $4\%$ to $10\%$.