Hyperelasticity

Digital materials fabricated by multi-material 3D printing are designed as controlled mixtures of stiff and compliant constituents, yielding effective responses that span more than an order of magnitude in apparent stiffness and exhibit strongly nonlinear, composition-dependent, and rate-dependent dissipative behavior. Classical finite-strain viscoelastic models represent such behavior with closed-form strain energy functions for equilibrium and non-equilibrium stresses as well as evolution of internal variables, which may limit flexibility when a single constitutive model is expected to generalize across materials and loading rates. Here, we present a data-driven multi-material constitutive modeling framework that generalizes a formulation by Bergström and Boyce. The proposed framework retains the structure of the classical model, namely multiplicative kinematics, invariant-based strain-energy functions, and a scalar dissipative evolution law directed along the normalized nonequilibrium deviatoric stress. For the equilibrium branch, the data-driven discovery framework either directly predicts closed-form model parameters as functions of composition or automatically constructs a polyconvex strain-energy function using neural ordinary differential equations (NODEs). The nonequilibrium branch kinetics are learned similarly, either by directly identifying closed-form parameters across compositions or by using appropriately constrained artificial neural networks. Using multi-rate uniaxial compression data across multiple material compositions, we show that the proposed formulation captures rate-dependent stiffness and hysteresis across compositions while preserving thermodynamic consistency.

Constitutive modeling under uncertainty remains a central challenge for reliable mechanics simulations, particularly when the available stress-deformation data are sparse, noisy, or heterogeneous. We propose interval and fuzzy physics-augmented neural networks (iPANNs and fPANNs) for uncertainty-aware hyperelastic constitutive modeling. iPANNs learn sparse lower, mean, and upper free energy density branches whose stresses, obtained by automatic differentiation, ultimately enclose noisy stress observations. In contrast to this deterministic interval description, fPANNs embed the learned iPANN branches into a fuzzy-set representation through alpha-cut interpolation, yielding a nested family of admissible responses. iPANNs and fPANNs encode mechanistic constraints - preserving objectivity, consistency and promoting polyconvexity - and smoothed L0 regularization promotes interpretable energy representations. The bound models are trained through a two-stage transfer-learning procedure in which a sparse mean constitutive response is learned first and then fine-tuned into lower and upper energy branches. We evaluate the framework on synthetic isotropic hyperelastic data with heteroscedastic noise, varying random realizations, shifted noise means, and varying noise magnitudes. The results show that the learned bounds enclose noisy stress observations while generalizing to the test set. Further, we examine the propagation of uncertainty through the mean, upper and lower bound predictions of the learned iPANN models in a finite element setting. The proposed framework provides a compact, physics-consistent route for distribution-free aleatoric uncertainty quantification in hyperelastic constitutive modeling, and propagation in downstream finite element simulations.

Data-driven material modeling techniques have gained significant attention due to their ability to capture complex constitutive behaviors beyond the limitations of classical material models. Physics-augmented neural networks (PANNs), which embed physical constraints directly into their architecture, combine the flexibility of machine learning with the reliability required for engineering simulations. This work presents an approach to integrate such network architectures into the explicit finite element solvers Simcenter Radioss and OpenRadioss (Siemens). A framework for transferring pretrained network architectures and their parameters to a standalone user material routine is developed. Networks are trained using PyTorch, though the procedure can be adapted to other frameworks such as TensorFlow, enabling the use of PANNs within existing finite element technology without requiring specialized solvers. Particular emphasis is placed on computational efficiency. The influence of network architecture on simulation performance is investigated, and strategies for reducing evaluation costs while preserving accuracy are discussed. Specifically, replacing the SoftPlus activation function with SQuarePlus is shown to reduce computational cost. A publicly available GitHub repository automates the generation of Fortran user material routines, requiring only the specification of the network architecture and trained parameters. An example impact simulation demonstrates that the generated PANN user material reproduces the nonlinear behavior characteristic of hyperelastic materials under large strains, providing a practical route toward machine-learning-based constitutive models in explicit finite element simulations.

Neural operators are increasingly used to warm-start Newton solvers for nonlinear PDEs, on the premise that a low test error places the initial guess inside the basin of attraction. We show that this premise is unreliable. An operator trained to the relative $L^2$ error $O(10^{-3})$ can still produce an initial state in which the discrete Jacobian is indefinite, because the mean-squared training controls error on average while leaving localized pointwise violations of the underlying physics. For a nearly incompressible hyperelasticity problem, we trace this to the predicted volume change: the operator disperses $\mathrm{det} F$ well away from one, and the resulting Jacobian acquires negative eigenvalues even when the predicted field is visually indistinguishable from the reference. At a small scale, this is a nuisance; at a multi-million degree-of-freedom scale, it is disqualifying, since the conjugate gradient and other Krylov solvers needed for memory-feasible Newton steps assume a definite spectrum. We then show that a short, label-free fine-tuning phase -- penalizing the operator against the discrete energy, with no additional solution data -- shifts the Jacobian spectrum back to positive definite. Combined with an inexact outer loop, this gives a warm-started Newton method that converges across the full loading range where the unregularized operator fails, reaching up to 5.4$\times$ wall-clock speedup over incremental continuation on a 3D problem with 6.4 million degrees of freedom.

Constitutive artificial neural networks (CANNs) provide interpretable material model discovery, but have so far been used in stress-supervised settings based on apparent stress-strain data from homogeneous tests. Because each test samples only a narrow loading path and provides homogenized rather than local stress information, robust discovery typically requires multiple loading modes to constrain the multidimensional response. This is challenging for soft biological tissues, where repeated testing, damage, and sample variability limit reliable information from a single specimen. Here, we combine CANNs with the stress-unsupervised full-field discovery framework EUCLID to identify sparse hyperelastic laws directly from displacement fields and reaction forces in one heterogeneity-inducing loading case. CANN-EUCLID minimizes equilibrium imbalance with sparsity-promoting regularization selecting compact active terms, without local stress measurements or a prescribed law. We evaluate the approach on isotropic and anisotropic benchmarks with prescribed ground-truth laws. When the ground truth is representable by the chosen CANN basis, our method recovers the correct terms with near-exact accuracy, including exponential terms with embedded parameters. When it is not contained in the basis, the method retains shared terms and approximates missing contributions using available basis functions. Generalization depends strongly on sampled deformation states: exponential strain-stiffening terms can be recovered accurately when sufficiently probed, but can produce large extrapolation errors when the stiffening regime lies outside the sampled domain. Forward FE validation simulations show that the discovered behavior accurately replicates the ground truth. These results establish stress-unsupervised CANN discovery as a promising framework for interpretable full-field constitutive model identification.

Predicting patient-specific facial soft-tissue deformation is critical for iterative orthognathic surgery planning. However, current computational methods face a strict accuracy-efficiency trade-off: high-fidelity Finite Element Methods (FEM) are computationally prohibitive, whereas pure deep learning models often produce biomechanically inconsistent results. While Physics-Informed Neural Networks (PINNs) offer a promising avenue, learning the complex heterogeneous mechanics of bone--soft-tissue interactions with only partial clinical supervision (i.e., outer facial surfaces) remains highly unstable. To overcome these challenges, we present PINNOCHIO, a novel physics-informed framework for facial soft-tissue simulation. PINNOCHIO introduces a hybrid sequential decomposition that explicitly decouples discontinuous bone--soft-tissue interface movements from continuous volumetric hyperelastic deformation. This structural separation enables stable training and facilitates a physics-enabled sim-to-real adaptation strategy, ensuring internal biomechanical consistency without requiring volumetric ground truth. Evaluated on a 40-patient clinical cohort, PINNOCHIO outperforms existing baselines in both surface accuracy and physical validity. Furthermore, it achieves a substantial speedup over FEM, successfully resolving the accuracy-efficiency trade-off to provide a highly reliable and practical tool for interactive surgical planning.

Data-driven surrogate models are an alternative to numerical homogenization of heterogeneous materials. In this contribution, a supervised learning approach is presented for predicting effective Lamé parameters of hyperelastic composites from low-dimensional microstructural descriptors. The data set is based on previously published numerical homogenization results for ensembles of two-phase stochastic microstructures generated by planar Boolean models, covering variations of inclusion shape, phase contrast, and area fraction; see Brändel, Brands, Maike, Rheinbach, Schröder, Schwarz and Stoyan (2022). A neural network is trained on combinations of scalar and curve-valued statistical descriptors, including the area fraction, a derived scalar shape descriptor $τ$, the two-point correlation function $S_2(r)$, and the lineal-path function $\ell(z)$. Additional data representing limiting cases of the parameter space are incorporated to stabilize training and improve extrapolation behavior. The surrogate is evaluated by leave-one-grain-type-out cross-validation in order to assess generalization to unseen grain geometries. Numerical results demonstrate that additional descriptors can reduce relative errors. A predictor trained with $τ$ and $S_2(r)$ provides a compact representation with good quantitative accuracy and regular dense response behavior. Adding the lineal-path function $\ell(z)$ further reduces the error at the available data points, indicating that it is a promising additional descriptor; however, dense post-training response evaluations show that improved pointwise accuracy does not automatically guarantee physically admissible behavior between sampled parameter values. This motivates future work on physically constrained surrogate models, loss formulations, bounded output parametrizations, and a more systematic representation of curve-valued geometric descriptors.

We present a novel formulation for mesh-free, reduced-order simulation of deformable hyperelastic objects. Existing work in reduced-order elastodynamic simulation represents the input geometry by either meshes, which can be difficult to obtain due to challenges in scanning and triangulating complex shapes, or by neural fields that require per-shape optimization. We propose to adopt a Reproducing Kernel Particle Method (RKPM) representation, which enables the construction of reduced-order skinning weights by solving a generalized eigensystem on the Hessian matrix of the elastic energy. We demonstrate that this formulation not only leads to a 40x training speedup compared with the per-shape optimization of neural fields, but also achieves lower simulation error when evaluated against the converged results of finite element method. We show our simulation results on a wide variety of objects in different representations including meshes and Gaussian splats, as well as the application of our method in the downstream task of robot simulation.

We propose a Weak-form Physics-Informed Neural Operator (WINO), a data-free framework that combines the efficiency of neural operators with the geometric flexibility of the $\varphi$-finite element method ($\varphi$-FEM). $\varphi$-FEM is an unfitted method that accommodates geometric variations without body-fitted meshes, where the domain geometry is represented by the level-set function $\varphi$. To impose the boundary conditions, Dirichlet problems adopt the $\varphi$-FEM lifting so only the homogeneous displacement contribution is learned, whereas traction-driven Neumann problems additionally predict the auxiliary fields necessary for the unfitted weak formulation. Parameters are trained by minimizing squared weak-form residuals aligned with $\varphi$-FEM together with squared penalties on the cut-cell auxiliary equations, which removes the need for large paired datasets of converged reference solutions. After training, WINO outputs can seed the nonlinear $\varphi$-FEM solvers as neural operator warm starts (NOWS), which reduce iteration counts relative to traditional cold-started solvers. Numerical benchmarks show that WINO achieves high accuracy below 0.04 across all benchmarks, while reducing total computational time by 50--80% compared with purely data-driven methods.

The identification of constitutive neural network models from heterogeneous full-field deformation data provides a robust alternative to traditional calibration methods based on homogeneous stress-strain experiments, particularly given the high dimensionality of trainable parameters. Existing approaches must balance generality, robustness, and computational efficiency: Conventional finite element model updating is broadly applicable but computationally demanding; weak-form methods offer efficiency but are sensitive to noise and data scarcity; neural operator models are highly expressive but require extensive training datasets. This work presents FE-MAD (Finite Element-Based Material learning via Automatic Differentiation), an end-to-end differentiable framework that integrates a constitutive neural network model within a JAX-FEM nonlinear solver and identifies its parameters through gradient-based minimization of a measurement-mismatch loss. Newton tangent stiffness and loss gradients are computed automatically using forward- and reverse-mode automatic differentiation throughout the entire pipeline, thereby removing the need for analytic adjoints or offline surrogate models. FE-MAD is demonstrated for two architectures: a grey-box Constitutive Artificial Neural Network (CANN), a polyconvex, fully connected model with high flexibility, and a white-box CANN, an expert-system network with phenomenologically interpretable strain-energy terms. Focusing on incompressible isotropic hyperelasticity, FE-MAD is evaluated on three open experimental datasets: (1) full digital image correlation (DIC) of a perforated tensile specimen, (2) a reduced-data scenario with a one-dimensional stretch profile and global force-displacement curve, and (3) a heterogeneous matrix-inclusion system in which both phases constitutive laws are identified and generalized to twenty-two previously unseen samples.

Differentiable simulation of soft bodies is a foundation for system identification, trajectory optimization, and Real2Sim transfer. Yet, existing methods such as the differentiable Projective Dynamics (DiffPD) struggle when faced with heterogeneous materials with extreme stiffness contrasts, hyperelasticity under large deformations, and contact-rich interactions, which are common scenarios in the real world. We present DiffPhD, a unified GPU-accelerated differentiable Projective Dynamics framework for heterogeneous materials that tackles these intertwined challenges simultaneously. Our key insight is a careful integration of: (i) stiffness-aware projective weights to embed heterogeneity into the global system; (ii) trust-region eigenvalue filtering lifted to the backward pass for stable hyperelastic gradients and a type-II Anderson Acceleration scheme with dual-gate convergence to stabilize forward iteration under large stiffness contrasts; and (iii) a unified GPU pipeline that reuses a single sparse factor across forward, backward, and contact computations, with stiffness-amplified Rayleigh damping folded into the same factor for heterogeneity-aware dissipation at zero recurring cost. DiffPhD achieves strict gradient accuracy while delivering up to an order-of-magnitude speedup over prior differentiable solvers on heterogeneous, hyperelastic, contact-rich benchmarks. Crucially, this speedup does not come at the cost of stability: DiffPhD remains convergent on stiffness contrasts up to 100x where prior PD solvers degrade. This unlocks end-to-end gradient-based optimization on regimes previously bottlenecked by either solver fragility or per-iteration cost -- shell--joint composite creatures, soft characters wielding stiff weapons, and soft-gripper robotic manipulation -- all handled within a single forward--backward pass.

Physics-informed operator learning is an attractive candidate for surrogate modeling of microstructures, especially in multiscale finite-element simulations. Its practical use, however, is often limited by the high cost of loss evaluation. We address this bottleneck by combining the Equilibrium Neural Operator (EquiNO) with the QR-based discrete empirical interpolation method (Q-DEIM). EquiNO learns only the modal coefficients of reduced displacement-fluctuation and first Piola-Kirchhoff stress representations built from periodic and divergence-free bases, thereby enforcing periodicity and mechanical equilibrium by construction. Q-DEIM then identifies a small set of spatial points through a column-pivoted QR factorization of the stress basis and restricts constitutive evaluations during training to these points alone. This makes full-batch second-order optimization practical for three-dimensional representative volume elements (RVEs). Homogenized first Piola-Kirchhoff stresses are recovered directly from the offline-averaged reduced stress modes, without the need to reconstruct the full stress field at inference time. We validate the framework on two three-dimensional finite-strain hyperelastic RVEs. Q-DEIM reduces the per-step training cost by roughly three orders of magnitude relative to full-field loss evaluation, while reduced homogenization achieves speed-up factors of order $10^3$ to $10^4$ over direct full-field computations. Despite relying on only a small number of offline snapshot loading paths for basis construction, the method accurately interpolates and extrapolates both microscopic stress fields and homogenized stresses, with prediction quality improving systematically as more snapshots are added.