THE OBJECTIVE OF THE PROPOSED THREE-YEAR PROJECT IS TO FORMULATE A 3D GIGA RESOLUTION LEVEL SET TOPOLOGY OPTIMIZATION FOR COMBINED STRUCTURAL (LOAD-CARRYING) AND THERMAL (HEAT REJECTING) FUNCTIONALITIES. THE KEY SCIENTIFIC INNOVATIONS ARE: (1) LEVEL SET TOPOLOGY OPTIMIZATION (LSTO) CROSSING 10^9 LENGTH SCALES USING OPENVDB; (2) OPENVDB-LSTO IN OPENMDAO; (3) LSTO WITH MULTIPLE MATERIAL; (4) THERMOMECHANICAL LSTO FOR HEAT CONVECTION WITH MOVING BOUNDARIES WITH CONDUCTION AND THERMOMECHANICS; AND (5) CASE STUDIES BASED ON ELECTRIC AIRCRAFT PROPULSION SYSTEM COMPONENTS DEMONSTRATING IMPROVED THERMAL-MECHANICAL PERFORMANCE COMPARED TO A BASELINE NON-COUPLED DESIGN. THE FUNDAMENTAL METHOD PROPOSED IN THE PROJECT IS LEVEL SET TOPOLOGY OPTIMIZATION WITH SPARSE DATE. TOPOLOGY OPTIMIZATION IS WELL KNOWN TO PRODUCE DESIGNS THAT DEPART SIGNIFICANTLY FROM THE TRADITIONAL DESIGNS. THE LEVEL SET BASED METHOD HAS AN ADDED ADVANTAGE OF PRODUCING CLEAR BOUNDARIES WHICH IS CHALLENGING IN THE TRADITIONAL ELEMENT-BASED METHODS (E.G. SIMP). THE LEVEL SET METHOD IS THUS PARTICULARLY SUITABLE FOR PHYSICS WHERE THE CLEAR BOUNDARIES ARE NEEDED TO DEFINE THE SURFACE PHYSICS SUCH AS CONVECTION. SMALL FEATURES ARE CONSIDERED BENEFICIAL FOR THERMAL MANAGEMENT AS HEAT TRANSFER PER UNIT AREA SCALES INVERSELY PROPORTIONAL WITH A CHARACTERISTIC DIMENSION AND THE SURFACE AREA-TO-VOLUME RATIO INCREASES WITH THE DECREASING DIMENSION ACHIEVING ENHANCED EFFICIENCY PER UNIT VOLUME. HENCE ARCHITECTED MATERIAL AND MICROLATTICES ARE COMMONLY STUDIED FOR THERMAL MANAGEMENT STRUCTURES. METAMATERIAL PROPERTIES SUCH AS NEGATIVE THERMAL EXPANSION HAS BEEN DEMONSTRATED. HOWEVER SUCH DESIGNS TYPICALLY ASSUME PERIODIC MATERIAL THUS OPTIMIZE A UNIT CELL. THIS PERIODICITY REQUIREMENT RESTRICTS THE DESIGN SPACE AND A WIDER DESIGN SPACE WILL BE SEARCHED BY ENABLING A 10^9 RESOLUTION WITHOUT PERIODICITY. THE STATE OF THE ART PUBLISHED IN NATURE 2017 OPTIMIZED A CRM WING WITH 10^9 ELEMENTS FOR THREE LOAD CASES. THEY MINIMIZED THE TOTAL COMPLIANCE UNDER LINEAR ELASTICITY WITHOUT COUPLING THE AERODYNAMICS AND REQUIRED THE SIMP METHOD ON 8000 PROCESSORS OVER FIVE DAYS. WE HAVE RECENTLY DEVELOPED A SPARSE DATA STRUCTURE BASED LEVEL SET METHOD AND DEMONSTRATED IT ON A GEOMETRY PROBLEM (NO FINITE ELEMENT ANALYSIS) MODELLED WITH 10^10 ELEMENTS WHICH SOLVED ON A DESKTOP WITH 56 PROCESSORS AND 64GB MEMORY OVER 5 HOURS. WE BELIEVE OUR COMPUTATIONALLY LEAN SPARSE LEVEL SET METHOD WILL MAKE TOPOLOGY OPTIMIZATION FOR THE COUPLED STRUCTURAL-THERMAL DISCIPLINES FEASIBLE. THE PROPOSED PROJECT WILL DEVELOP A GIGA RESOLUTION TOPOLOGY OPTIMIZATION FOR COUPLED DISCIPLINES OF CONDUCTION CONVECTION AND THERMAL AND MECHANICAL LOADS. THIS WILL BE ACHIEVED OVER THREE YEARS BY BUILDING ON OUR EXISTING EXPERTISE IN (1) LARGE SCALE LEVEL SET TOPOLOGY OPTIMIZATION; (2) CONDUCTION; (3) THERMAL-MECHANICAL TOPOLOGY OPTIMIZATION; AND (4) TOPOLOGY OPTIMIZATION IN OPENMDAO. WE WILL FORMULATE NOVEL TOPOLOGY OPTIMIZATION FOR CONVECTION WITH A MESHFREE METHOD (E.G. REPRODUCING KERNEL PARTICLE METHOD). THIS WILL BE COMBINED WITH CONDUCTION AND THERMOS-MECHANICAL STRESS TOPOLOGY OPTIMIZATION IN OPENMDAO. TWO NUMERICAL CASE STUDIES WILL BE INVESTIGATED: (1) WINGBOX WITH THERMAL MANAGEMENT PROPERTIES AND (2) HEAT EXCHANGING ELECTRIC MOTOR MOUNTING SYSTEMS. THE PROPOSED WORK ADDRESSES THE NASA S STRATEGIC OBJECTIVE (3.2) TO TRANSFORM AVIATION THROUGH REVOLUTIONARY TECHNOLOGY RESEARCH BY ENABLING THE DISCOVERY OF REVOLUTIONARY STRUCTURAL-MATERIAL SYSTEMS. THE ENABLER IS NOVEL DESIGN OPTIMIZATION WHICH FALLS INTO TTT S REVOLUTIONARY TOOLS AND METHODS SUB-PROJECT SPECIFICALLY IN THE MDAO AND SYSTEMS ANALYSIS DISCIPLINE TO ASSESS AND INTEGRATE THE SYSTEMS LEVEL BENEFITS OF COUPLED STRUCTURAL AND HEAT TRANSFER DISCIPLINES. IT ALSO ADDRESSES THE CHALLENGES IN THE MATERIALS AND STRUCTURES DISCIPLINE BY PROVIDING A SYSTEMATIC OPTIMIZATION FORMULATION TO DESIGN MULTIFUNCTIONAL LIGHT WEIGHT STRUCTURES.