We propose a new model-order reduction framework to poorly reducible problems arising from parametric partial differential equations with geometric variability. In such problems, the solution manifold exhibits a slowly decaying Kolmogorov $N$-width, so that standard projection-based model order reduction techniques based on linear subspace approximations become ineffective. To overcome this difficulty, we introduce an optimal morphing strategy: For each solution sample, we compute a bijective morphing from a reference domain to the sample domain such that, when all the solution fields are pulled back to the reference domain, their variability is reduced. We formulate a global optimization problem on the morphings that maximizes the energy captured by the first $r$ modes of the mapped fields obtained from Proper Orthogonal Decomposition, thus maximizing the reducibility of the dataset. Finally, using a non-intrusive Gaussian Process regression on the reduced coordinates, we build a fast surrogate model that can accurately predict new solutions, highlighting the practical benefits of the proposed approach for many-query applications. The framework is general, independent of the underlying partial differential equation, and applies to scenarios with either parameterized or non-parameterized geometries.

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