A correlation between density maximization and size segregation for packings of polydisperse particles in geometric confinement has been discovered, through the derivation of a general solution for the densest-packed zigzag arrangements of polydisperse particles. This solution is a size-graded structure in which the larger a particle the closer it is located to either end of the system, such that the smaller particles in the interior are encapsulated by the larger ones away from it. Any pair of different-sized adjacent particles is a grain-boundary-like configuration that reduces the overall packing efficiency of the system, and this solution corresponds to a minimization of excess-volume contributions from grain-boundary-like configurations of different-sized particles as a result of the clustering of equal- or like-sized particles. Our findings provide new insights into how structural order of polydisperse particles emerges in confined settings.

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• Grain boundaries
• Granular packing
• Granular segregation
• Polydisperse systems