This paper presents a method for optimal design of compliant mechanism
topologies. The method is based on continuum-type topology optimizati
on techniques and finds the optimal compliant mechanism topology withi
n a given design domain and a given position and direction of input an
d output forces. By constraining the allowed displacement at the input
port, it is possible to control the maximum stress level in the compl
iant mechanism. The ability of the design method to find a mechanism w
ith complex output behavior is demonstrated by several examples. Some
of the optimal mechanism topologies have been manufactured, both in ma
croscale (hand-size) made in Nylon, and in microscale (<.5mm)) made of
micromachined glass.