Physics-Informed Neural Networks and Sequence Encoder: Application to heating and early cooling of thermo-stamping process

Accurate thermal modeling is essential in metal additive manufacturing (AM) for understanding the process-structure-property chain. Physics-informed neural networks (PINNs) offer effective surrogate thermal modeling by minimizing physics-based residual losses at collocation points. However, prior works typically rely on manually-crafted, static collocation sampling strategies, which are neither principled nor scalable across process conditions, hindering their generalization capability. In this work, we provide theoretical analysis through empirical risk minimization, showing that process condition-aware adaptive sampling is strictly more favorable than conventional static sampling for generalization. Building on this insight, we propose an adaptive sampling strategy within a two-stage framework: (1) a conditional Flow Matching model that learns approximate high-residual distributions across different process conditions, and (2) a mixed sampling strategy combining this distribution with a domain-informed base distribution to generate adaptive collocation points for refining the PINN predictor. Experiments on metal AM numerical benchmarks demonstrate that our method consistently outperforms state-of-the-art PINN baselines, achieving an average 62.1% reduction in relative $L_2$ error under an identical collocation budget, by capturing process-dependent heat dissipation regions often overlooked in the literature. To the authors' knowledge, this is the first adaptive sampling strategy for PINNs in metal AM, contributing to the enhanced generalization and broader applicability.

Accurate thermal modeling in metal additive manufacturing (AM) is essential for understanding the process-structure-performance relationship. While prior studies have explored generalization across unseen process conditions, they often require extensive datasets, costly retraining, or pre-training. Generalization across different materials also remains relatively unexplored due to the challenges posed by distinct material-dependent thermal behaviors. This paper introduces a parametric physics-informed neural network (PINN) framework for zero-shot generalization across arbitrary materials without labeled data, retraining, or pre-training. The framework adopts a decoupled parametric PINN architecture that separately encodes material properties and spatiotemporal coordinates, fusing them through conditional modulation to better align with the multiplicative role of material parameters in the governing equation and boundary conditions. Physics-guided output scaling derived from Rosenthal's analytical solution and a hybrid optimization strategy are further incorporated to enhance physical consistency, training stability, and convergence. Experiments on bare plate laser powder bed fusion (LPBF) across diverse metal alloys, including both in-distribution and out-of-distribution cases, demonstrate effective zero-shot generalizability along with superior training efficiency. Specifically, the proposed framework achieved up to a 64.2% reduction in relative L2 error compared to the non-parametric baseline while surpassing its performance within only 4.4% of the baseline training epochs. Ablation studies confirm that the proposed framework's components are broadly applicable to other PINN-based approaches. Overall, the proposed framework provides an efficient and scalable material-agnostic solution for zero-shot thermal modeling, contributing to more flexible and practical deployment in metal AM.

Physics-informed neural network (PINN) training minimizes a weighted combination of partial differential equation (PDE), boundary-condition, and initial-condition losses. Because adaptive methods modify these weights during training, their weighted total losses are not always directly comparable. We compare fixed-weight PINN, gradient-normalized PINN (GNPINN), and a rule-based adaptive controller (AgenticPINN) under matched settings on a heat-equation benchmark and a simplified Czochralski-oriented thermal-fluid problem. In the crystal-growth MLP experiment, adaptive control reduced the PDE residual from the order of $10^{-5}$ to $10^{-6}$, while the boundary-condition loss increased from the order of $10^{-5}$ to $10^{-2}$. On the heat-equation benchmark, GNPINN achieved the lowest relative $L_2$ field error (0.054), whereas AgenticPINN obtained the smallest PDE residual but a relative $L_2$ error of 1.368. Gaussian-process surrogates were additionally evaluated using case-wise holdout tests on corrected Czochralski CFD parameter sweeps. The temperature-field error for the temperature sweep was approximately 6%, whereas the axial-velocity error for the crystal-rotation sweep was approximately 42%. These findings show that adaptive control can improve equation satisfaction while weakening other physical constraints. PINN training should therefore be evaluated using separate PDE, boundary-condition, and solution-error metrics rather than weighted total loss alone.