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Designing openings in structures, such as windows in airplanes or cable conduits in engines, often requires engineers to reinforce the surrounding areas for structural integrity. However, these reinforcements can sometimes introduce new structural weaknesses elsewhere.

Researchers from Princeton and Georgia Institute of Technology have developed an innovative technique to maintain structural integrity by essentially "hiding" the opening from surrounding forces. Instead of reinforcing the opening to protect against a few specific forces, this new method reorganizes the forces around the opening to avoid affecting it.

In a paper titled "Unbiased Mechanical Cloaks," published in the Proceedings of the National Academy of Sciences, the researchers describe how they surrounded openings with microstructures designed to counteract various external forces that cause stress, movement, or deformation. These microstructures are carefully shaped and oriented to handle the most challenging loads, enabling designers to address multiple stresses simultaneously.

"Imagine a plate with a hole in it. If you apply stress, the hole causes a concentration of stress, and the plate will fail sooner than it would without the hole," explained Emily D. Sanders, an assistant professor of mechanical engineering at Georgia Tech. "We want to design something around this hole so that it feels like the hole doesn’t even exist."

Glaucio Paulino, a principal author of the study and the Margareta Engman Augustine Professor of Engineering at Princeton, noted that while designers usually reinforce structures at openings like windows or tunnels, doing so can sometimes introduce new stress in other directions, creating additional problems. The goal of the cloaking technique is to redirect external forces around the opening without introducing new stress points.

The researchers drew inspiration from tree knots, where microstructures seem to direct forces around intrusions like branches or roots, preserving the tree's structural strength. They aimed to engineer a similar solution for manufactured materials.

The technique relies on two optimization problems to select the best solutions from a range of choices. The first optimization identifies the worst-case loads that could challenge the structure, taking into account that loads on a structure can vary depending on factors such as weather or movement.

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"Any structure can potentially have an infinite number of loads. Every time you drive your car, the loads are different, the wind may blow in different directions, or the temperature may fluctuate," Paulino said.

The researchers found that calculating six to 10 of the worst-case loads for a structure produced the most effective results. They then used this information to solve the second optimization problem, designing and deploying microstructures to surround the opening.

"This optimization technique represents a breakthrough for achieving the invisibility of a defect, regardless of the direction of external forces," said Davide Bigoni, a professor of solid and structural mechanics at the Universita' di Trento in Italy. "This omnidirectional cloaking has broad applications, from ensuring mechanical stress neutrality in organ tissue replacement to enhancing restoration of artwork."

This concept is similar to cloaking techniques developed to hide objects from the electromagnetic spectrum, such as stealth technology in aircraft. Although the equations for solid materials are more complex than those for electromagnetism, Paulino pointed out that the goal remains the same: to "hide" structural weaknesses and ensure optimal performance under various conditions.