CAST: Cast-Admissible Generative Design and Shape Optimization with Paired Depth Images

Engineering design often starts from a 2D sketch that fixes style and proportions, yet the subsequent 3D shape optimization relies on learned generative priors to keep the geometry valid. However, these priors are agnostic to the sketch: while they admit a valid design by correcting a drifted proposal back to its training distribution, they often correct it towards the high-density region, ignoring the specified design. We introduce AnchorGen, a rectified-flow framework trained unconditionally on the concatenated shape and sketch latents of paired data. The learned manifold represents the joint distribution of shape-sketch pairs, so constraining the sketch component restricts the iterate to the sub-manifold of shapes consistent with a target style. Since training employs no conditioning signal, the constraint is imposed at inference: gradient descent optimizes the shape latent to minimize a differentiable drag surrogate, while constraining the sketch latent to remain close to the target sketch via a token-wise cosine penalty. A single model thereby supports design-preserving optimization, dimensionally explicit design edits, and sketch-only synthesis.

Natural load-bearing patterns such as leaf venation, trabecular bone, and spider webs achieve high stiffness per unit mass, yet classical topology optimizers rarely reach such geometries, and few let engineers express structural design intent through natural language. This work treats a frozen text-to-image diffusion model as a training-free source of design knowledge and distills it into the physics loop of density-based topology optimization via score distillation sampling, so that a text prompt becomes an explicit, machine-interpretable representation of engineer intent. The prompt-induced generative gradient and the finite element sensitivity are combined at every iteration, letting physics decide which prompt-induced features survive. In 245 primary SDS runs spanning four geometric domains and two physics regimes, 38 of 49 prompt--domain combinations achieved statistically significant compliance reductions (up to $-31.5\%$ mechanical and $-23.0\%$ thermoelastic), outperforming gradient-based baselines. Cross-domain morphological analysis identifies a recurring structural signature of improvement: in most domains the generative prior suppresses dead-end branches in the rib skeleton, with endpoint--compliance correlation $r = +0.56$ to $+0.99$. A Heaviside projection with $β$-continuation resolves a pronounced intermediate-density tendency in this diffusion--physics coupling ($42.6\%$ to $<3\%$), and an automated skeleton-based pipeline converts optimized density fields into \rev{candidate geometry ready for computer-aided design. By retargeting the generative prior across domains, loading conditions, and physics objectives through a change of text prompt, with each new problem's physics setup specified separately, the framework uses a pretrained generative model as a reusable, training-free prior for engineering design.

Engineering inverse design is often limited by the high computational cost of iterative solvers for optimization problems constrained by partial differential equations (PDEs) and by their sensitivity to initialization. Deep generative models can produce candidate designs without rerunning the simulator at inference time. Generative adversarial networks (GANs) sample in one forward pass, whereas diffusion models require iterative reverse-time integration. In this work, we add conditional flow matching (CFM) to EngiOpt and compare it with a conditional diffusion model and a conditional generative adversarial network (cGAN) on structural (beams2d) and thermal (heatconduction2d) benchmarks from EngiBench using the same downstream optimization protocol. We use cumulative optimality gap (COG) and final optimality gap (FOG) as the primary metrics for evaluating the generated designs as warm starts for gradient-based refinement. On the evaluated EngiOpt implementations and two EngiBench tasks, CFM achieves the lowest measured COG, FOG, maximum mean discrepancy (MMD), and volume-fraction deviation on both tasks. CFM has mean volume-fraction deviations of 0.4% and 1.0% on beams2d and heatconduction2d, respectively, compared with 3.8% and 11.2% for diffusion. At Euler s = 16, CFM achieves 53.2 samples/s on beams2d, about 66 times the measured throughput of the evaluated diffusion baseline using 1000 network evaluations under the same timing protocol, with COG 1.182 +/- 3.126, compared with 1.173 +/- 3.100 for Euler s = 32. Across the two tasks, CFM produces warm starts with lower measured COG than both baselines and uses fewer network evaluations than diffusion.