Reduced-Space Multi-Fidelity Bayesian Optimization of Process Simulation Models

Black-box optimization is a ubiquitous problem in science and engineering, often dealing with expensive objective functions with cheaper lower-fidelity proxies available. Multi-fidelity Bayesian optimization (MF-BO) is a principled approach to this problem, leveraging correlations across different fidelities when querying the objective. However, for many important MF-BO tasks, the true highest-fidelity function is prohibitively expensive to be part of the optimization loop. Nevertheless, practitioners often have gold standard data (observations of the highest-fidelity function) obtained from previous experiments that might provide information for the current task. For instance, in molecular optimization, chemists often pick the top-$k$ candidate molecules using various computer simulations, and later reveal their true objective function values. In this work, we demonstrate the suboptimality of standard MF-BO algorithms in the real-world scenarios above, even under ideal assumptions. Next, we mitigate this problem by incorporating historical high-fidelity data accompanied by task descriptors---which can be explicitly given or extracted from unstructured metadata. We demonstrate the effectiveness of our methods on synthetic functions, as well as real-world problems in chemistry and hyperparameter optimization.

Active multi-fidelity surrogate modeling is developed for multi-condition airfoil shape optimization to reduce high-fidelity CFD cost while retaining RANS-consistent aerodynamic metrics. The framework couples a low-fidelity-informed Gaussian process regression transfer model with uncertainty-triggered sampling and a synchronized elitism rule embedded in a hybrid genetic algorithm. Low-fidelity XFOIL evaluations provide inexpensive features, while sparse RANS simulations are adaptively allocated when predictive uncertainty exceeds a threshold; elite candidates are mandatorily validated at high fidelity, and the population is re-evaluated to prevent evolutionary selection based on outdated fitness values produced by earlier surrogate states. The method is demonstrated for a two-point problem at $Re=6\times10^6$ with cruise at $α=2^\circ$ (maximize $E=L/D$) and take-off at $α=10^\circ$ (maximize $C_L$) using a 12-parameter CST representation. Independent multi-fidelity surrogates per flight condition enable decoupled refinement. The optimized design improves cruise efficiency by 41.05% and take-off lift by 20.75% relative to the best first-generation individual. Over the full campaign, RANS evaluations were required for only 14.78% and 9.5% of the condition-specific candidate evaluations at cruise and take-off, respectively. These percentages quantify the reduction in high-fidelity usage relative to the fixed automated RANS workflow adopted as the high-fidelity reference in this study.

We introduce BASIL, a user-friendly desktop application for process optimization. BASIL employs a Bayesian approach, incorporating special acquisition functions that can be used to solve both single and multi-objective optimization problems. It provides a graphical interface that enables users to input their experimental parameters, optimization objectives, and legacy data. This is then used to build surrogate models, which are coupled with acquisition functions to guide and optimize a process towards a desired objective. To facilitate model building, BASIL provides a variety of predefined surrogate model templates. BASIL can be used to optimize any arbitrary experiment or process with known, user-defined input variables, optimization objectives, and defined output.