This study developed a discrete topology optimization procedure for the simultaneous design of ply orientation and thickness for carbon fiber reinforced plastic (CFRP)-laminated structures. A gradient-based discrete material and thickness optimization (DMTO) algorithm was developed by using casting-based explicit parameterization to suppress the intermediate void across the thickness of the laminate. A benchmark problem was first studied to compare the DMTO approach with the sequential three-phase design method using the free size, ply thickness, and stacking sequence of the laminates. Following this, the DMTO approach was applied to a practical design problem featuring a CFRP-laminated engine hood by minimizing overall compliance subject to volume-related and functional constraints under multiple load cases. To verify the optimized design, a prototype of the CFRP engine hood was created for experimental tests. The results showed that the simultaneous discrete topology optimization of ply orientation and thickness was an effective approach for the design of CFRP-laminated structures.
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