Poli-USP · Dept. of Mechatronics (PMR)

Design Optimization & Generative Engineering

We develop methods that let physics, mathematics and AI decide the shape of engineering devices — then we build them and test them.

A lab where the optimizer draws the machine

Founded by Prof. Luís Sá in 2023, the DO&GE Lab tackles multidisciplinary problems — structural, thermal and fluid flow — by combining parametric optimization, topology optimization and machine learning. The goal is simple to state and hard to reach: devices with maximum performance, efficiency and sustainability.

Our work has produced 33+ peer-reviewed papers and 440+ citations, in collaboration with Imperial College London, the Technical University of Denmark (DTU) and the National Laboratory for Scientific Computing (LNCC).

33+peer-reviewed publications
440+citations
38co-authors worldwide
2patent families

Approach

Three ways to find the best design

Fmin compliance · V ≤ V*
01

Classical topology & parametric optimization

Algorithms redistribute material or tune parameters to reach highly efficient geometries under structural, thermal or fluid constraints — SIMP, TOBS (binary structures), topological derivatives and level-set methods.

z ~ 𝒩(0, I)same BCs → many designs
02

Generative design powered by AI

Neural networks explore vast design spaces beyond human intuition. From boundary conditions and a few past designs, they propose novel solutions that balance competing goals — stiffness vs. weight, pressure drop vs. flow rate.

x* (predicted optimum)f̂(x) ± σ
03

Data-driven optimization

Surrogate models trained on historical designs predict performance almost instantly and accelerate convergence — especially for expensive problems like heat exchangers and complex flow devices.

Research lines

Where we apply it

01

Topology optimization of fluid flow devices

Our flagship line — from microfluidic channels to industrial turbomachinery, using integer linear programming, topological derivatives and continuous boundary propagation.

  • ILP with binary design variables — no grayscale
  • Continuous boundary-condition propagation for multiphysics
  • Geometry trimming to reduce seepage
  • Discrete adjoints for incompressible and compressible flows
02

Fuel cell design (PEMFC & SOFC)

Redesigning flow channels of proton-exchange-membrane and solid-oxide fuel cells.

  • Multilayered pseudo-3D, two-phase, nonisothermal PEMFC — anode and cathode optimized together
  • Radial flow fields for circular PEMFCs with water management
  • SOFC channel layouts with design-variable propagation and 3D multiphysics FEM
03

Compressible & turbulent flow optimization

Pioneering formulations for subsonic compressible and rotating turbulent flows.

  • Density-based models coupled to compressible Navier–Stokes
  • Spalart–Allmaras turbulence in rotating reference frames
  • Diffusers, nozzles and aerodynamic components
04

Rotating machinery & labyrinth seals

Rotors, Tesla-type pumps and labyrinth seals designed by topology optimization — and validated on the bench.

  • Simultaneous rotor–stator multi-component design
  • Tesla pumps from 2D swirl-flow models
  • Seals under compressible turbulent flow, tested with 3D-printed prototypes
  • Forward/backward multi-objective seals — Best Oral Presentation, ETRI 2024
05

Biomedical devices

Optimization and generative design applied to medical devices.

  • Design, optimization, manufacturing and testing of ventricular assist pumps
  • 3D-printed prototypes validated for flow and pressure head
  • Patents for ventricular assist devices
Collaborating with Imperial College LondonTechnical University of Denmark (DTU)LNCCRCGI — USP

People

Who's in the lab

Researchers and students currently supervised or co-supervised by Prof. Sá.

Postdoc

Andre Luis Ferreira da Silva

Since 2024

Ph.D. · Since 2025

Alberto Lemos Dúran

Topology optimization method applied to the design of compressor impellers for supercritical CO₂ considering resonance frequency and vorticity local constraints

Ph.D. · Since 2024

Gabriela Alves Barbosa

Simulation and Optimization of Solid Oxide Fuel Cells

M.Sc. alumnus · 2024

Lucas Neves Braga Soares Ribeiro

Experimental Study of Labyrinth Seal Designed by Topology Optimization

Thesis ↗
Examination boards 4
  • M.Sc. Defense · 2025José Pereira Ramos JuniorTopology Optimization Based on Moving Morphable Components Applied to Passive Flow Control Devices
  • Ph.D. Qualifying · 2025Rômulo Luz CortezNumerical filters for topology optimization with binary design variables applied to rotormachinery
  • Ph.D. Qualifying · 2024Felipe Silva MaffeiA Methodology for Topology Optimization of Turbulent and Compressible Flows for Large-Scale Applications
  • M.Sc. Qualifying · 2025José Pereira Ramos JuniorTopology Optimization Based on Moving Morphable Components (...)

Join the lab

We’re always looking for curious people

Pick the path that fits you. If you're unsure, write anyway — we'll find the problem that fits.

Undergraduate · IC & TCC

For Mechanical, Mechatronics and related students who want hands-on research. No prior optimization experience needed — curiosity and commitment are what matter.

Topics
See the open topics on the Research page.
Requirements
Enrolled at Poli-USP or a partner institution; basic Python or MATLAB; interest in numerical methods or machine learning.
How to apply
Send your transcript and a short statement of interest.

M.Sc. & Ph.D.

Positions in every research line. You'll develop original research, publish in international journals and present at conferences.

Background
Degree in Engineering, Physics, Applied Mathematics or Computer Science; strength in FEM/numerical methods, fluid mechanics, optimization or ML; Python, C/C++ or MATLAB.
Funding
Typically FAPESP, CNPq or CAPES scholarships.
How to apply
Send your CV, transcript and a short research proposal aligned with one of the lab’s lines.

Postdoctoral researchers

Openings arise periodically, usually tied to funded projects (FAPESP, Shell/RCGI).

Ideal profile
Experience in topology optimization, computational fluid dynamics or scientific machine learning.
How to apply
Reach out with your CV and research interests.