The performance of high-field magnets is increasingly constrained not by the limits of High-Temperature Superconducting materials, but by the structural systems needed to withstand the intense Electro-Magnetic forces they produce. In response to this challenge, this work presents a design-driven methodology for optimizing the reinforcement structures of 52 cm bore wide HTS magnets under development at Renaissance Fusion, aimed at achieving magnetic fields up to 10 T on the plasma axis. A custom Topology Optimization tool, based on the Solid Isotropic Material Penalization method and implemented entirely in PyMAPDL, was employed to guide the mechanical design of the magnet reinforcements. Starting from a large design domain (11.3 tons per sector), Topology Optimization with varying volume fractions produced lightweight structures, down to 3.93 tons, that meet strict mechanical constraints on magnet displacement (1 mm), magnet strain (0.5%) and global stress (800 MPa). Then, a second optimization stage using extrusion constraints methodologies was employed to further optimize the structure while ensuring manufacturability. Recurring features from these runs informed the development of a parametric model, enabling further refinement and a final mass of 1.20 t. The final structure, segmented into sub-components for a feasible assembly procedure, retained the required mechanical performance while ensuring ease of manufacturing using conventional processes. This magnet design demonstrate the applicability and benefits of our multi-stage constrained topology optimization method for advancing the structural design of high-field and compact stellarators.
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