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Purpose

This research aims to present a 3D multi‐objective approach regarding both magnetic and thermal characteristics associated with design of actuators.

Design/methodology/approach

The adjoint variable topology sensitivity equations are derived using the continuum method for 3D optimization. Convection interpolation function is proposed for density method of topologies such that convection term can be taken into consideration for practical design in the process of the optimization. In application of a C‐core actuator, the sensitivity is verified using the finite difference method (FDM). The proposed method is applied to the C‐core actuator and a single‐phase induction motor.

Findings

The thermal field is much more sensitive than electromagnetics that the weighing factor is investigated in the SPIM. Optimal topology result shows that cutting is needed.

Originality/value

A 3D topology optimization for magnetic and thermal systems using the finite element method is proposed.

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