HPG-Diff: Hierarchical physics-guided diffusion with differentiable connectivity constraints for topology optimization

Physics-informed diffusion models typically enforce PDE constraints only on final outputs, leaving intermediate representations unconstrained and prone to shortcut learning under shifted boundary conditions. We introduce REPA-P, a teacher-free, architecture-agnostic framework that aligns intermediate features with physical states using first-principles residuals. REPA-P attaches lightweight $1{\times}1$ projection heads to selected layers, decodes hidden activations into physical quantities, and applies PDE residual losses during training. These heads are discarded at inference, introducing zero overhead. Across four PDE tasks, including Darcy flow, topology optimization, electrostatic potential, and turbulent channel flow, REPA-P accelerates convergence by up to $2{\times}$, reduces physics residuals by up to $66.4\%$, and improves out-of-distribution robustness by up to $49.3\%$, with consistent gains on both U-Net and Diffusion Transformer backbones. Ablations show that supervising a small set of intermediate layers captures most benefits and complements output-level physics losses. Code is available at https://github.com/Hxxxz0/REPA-P.

Density-based topology optimization is typically structured as a nested sequence of material updates, structural analyses, and sensitivity assessments. While neural density parameterization and dual-field physics-informed approaches provide data-free alternatives, most existing methods represent density and displacement as coordinate fields and make limited use of the discrete relationships inherent in the finite element mesh. The present study introduces HGTO, a unified graph-based formulation that extends complete neural topology optimization from coordinate space to finite-element graph space. Element densities are parameterized on the element graph derived from the mesh, and the structural state is determined on the corresponding node--element hypergraph. Finite element kinematics, numerical quadrature, constitutive response, and force assembly remain explicitly defined operations within the differentiable computation. The material field and equilibrium state are therefore coupled through a common finite-element incidence structure. Numerical studies show compliance comparable to conventional density-based optimization at substantially lower computational cost than a representative coordinate-based dual-field neural method. The same coupled formulation accommodates high-resolution and irregular meshes, three-dimensional structures, finite deformation, and elastoplastic response.

Topology optimisation (TO) often requires repeated finite element analysis and sensitivity-based material updates, which can be costly when multiple candidate designs are needed under varying physical and design conditions. Generative TO offers a route to rapid design exploration, but existing models may rely on adversarial training, long reverse-diffusion sampling, or external guidance to maintain structural feasibility and physical consistency. This study develops a flow matching-based topology optimisation (FMTO) framework for conditional topology generation. Linear FMTO is first formulated as an endpoint-based baseline by interpolating between a Gaussian source field and the BESO reference topology. To introduce mechanically meaningful intermediate states, a trajectory-aware FMTO formulation is proposed, where volume-fraction-indexed BESO states are used to construct the probability path and target velocity field. This incorporates physics-guided optimisation history into generative flow learning without adding inference-time optimisation. A path--velocity mismatch analysis explains why moderate trajectory weighting can improve generation stability, whereas excessive guidance may over-constrain the learned transport. Numerical examples show that FMTO generates diverse topology candidates with improved compliance-related performance, volume-fraction satisfaction, topology fidelity, and substantially fewer sampling steps than a diffusion-based baseline. Under limited training data, trajectory-aware FMTO achieves the best overall performance with a moderate trajectory weight. Studies on trajectory-anchor density and three-dimensional topology generation further demonstrate the influence of path design and the applicability of the proposed framework beyond two-dimensional problems.