Geometry-Preserving Reduced-Order Modeling via Immersed Tensor Decomposition (ITD)

Body-fitted finite-element methods deliver high-order accuracy but hinge on a clean, watertight, conforming mesh, a requirement that breaks down for the geometrically imperfect CAD assemblies, image-based volumetric data, and voxel-native designs that pervade biomedical engineering and additive manufacturing, where mesh generation has become the dominant cost of the analysis cycle. Immersed methods on regular background Cartesian grids sidestep body-fitted meshing, but classical implementations integrate over irregular cut subdomains, destroying the tensor-product structure that enables separable, reduced-order methods such as tensor decomposition. In this paper we propose the \emph{Immersed Tensor Decomposition} (ITD) framework, which couples a mesh-free geometric representation via body-fitted function with the separable C-HiDeNN-TD reduced-order solver to enable large-scale simulation directly on regular background voxel meshes. The geometry is encoded in three steps: a signed-distance function represents the boundary, a body-fitted function $\Phi$ approximates it with controllable error, and a low-rank Tucker decomposition provides model-order reduction; for a fixed grid spacing $h$, accuracy is improved by raising the approximation order of C-HiDeNN interpolation up to degree $p$ with a linear background mesh. The central contribution is an exact Dirichlet formulation that enforces the boundary condition strongly by multiplying the trial function with $\Phi$, so that $u=g$ holds by construction without any variational penalty or interface quadrature. We establish an a priori error estimate for the formulation and assess it on canonical 2D/3D domains, demonstrating optimal convergence and robustness on non-Cartesian geometries discretized by regular voxel meshes.