A Hybrid Quantum-Classical Approach for Melt Pool Prediction in Laser Powder Bed Fusion

This work investigates the implementation of artificial intelligence and machine learning (AI/ML) for real-time monitoring in laser powder bed fusion (LPBF) additive manufacturing. We developed a binary image classification framework for distinguishing normal and abnormal melt pool images using a balanced dataset of 1,200 images collected from Nickel superalloy 625 on the NIST AMMT platform. The study evaluates accuracy and inference time based on control requirements and hardware limitations of open-architecture LPBF machines. We benchmark three transfer learning architectures (ResNet50, EfficientNetB0, and MobileNetV2) against two Random Forest approaches: one trained on EfficientNetB0 feature embeddings (hybrid) and one trained on raw pixel features (baseline). Images are stratified into 80/20 train-test splits, with a further 90/10 validation split on the training set, and undergo standardized resizing, normalization, and label-preserving data augmentation to emulate realistic process variability. Each model is evaluated using accuracy, precision, recall, F1 score, and area under the receiver operating characteristic curve (AUC), along with training time, inference latency, and CPU & GPU usage to capture deployability constraints relevant to factory-floor monitoring. The hybrid EfficientNetB0-plus-Random Forest approach achieves the best performance on the held-out test set, with an F1 score of 0.9451, accuracy of 0.9458, and AUC of 0.9904, while maintaining sub-millisecond per-image inference (1.15 ms). In contrast, purely deep learning models exhibit significantly higher inference times with lower accuracy. These results demonstrate that combining pre-trained convolutional features with classical ensemble methods provides a robust, computationally efficient route to real-time melt pool anomaly detection in data-limited additive manufacturing environments.

Most multimodal learning methods improve how heterogeneous representations are aligned and fused, while post-fusion enhancement remains less explored. We propose Parallel Quantum Feature Augmentation (PQFA), a hybrid quantum-classical framework that applies multiple shallow variational quantum circuits to fused multimodal features. Text and image representations extracted by frozen RoBERTa and ViT encoders are processed through bidirectional cross-attention, attentive pooling, and adaptive gated fusion. The fused feature is then amplitude-encoded into parallel quantum circuits, whose measurement readouts are concatenated with the classical representation for prediction. We evaluate PQFA on MM-IMDb and N24News through controlled comparisons using the same encoders, fusion backbone, data splits, projection dimension, and augmentation output width. PQFA consistently outperforms both the fusion backbone without quantum augmentation and a width-matched MLP augmentation baseline, while using approximately 2.2K augmentation parameters compared with 24.0K for the MLP branch. Missing-modality experiments further show improved robustness when textual or visual inputs are incomplete, with particularly clear gains when the more informative textual modality is severely degraded. Controlled ablations and feature-space analyses indicate that the improvement cannot be reproduced by random feature mappings, increased classical width, or untrained quantum transformations. Quantum-state diagnostics additionally show stable predictive performance across the tested simulated noise levels and distinct branch-specific transformations of the encoded states. These results establish PQFA as an effective and parameter-efficient strategy for post-fusion augmentation in hybrid quantum-classical multimodal learning.

Many applications in quantum simulation, quantum chemistry, and quantum machine learning require not a single quantum state but an ensemble of states characterizing the heterogeneity of a target system. Preparing such ensembles state-by-state is prohibitive in both variational and fault-tolerant settings, thereby motivating a generative modeling approach. We introduce latent-conditioned parameterized quantum circuits (LPQCs), a hybrid quantum-classical framework in which classical neural networks map a latent variable sampled from a prior distribution to the parameters of a parameterized quantum circuit. We prove that LPQCs are universal approximators for probability measures over density operators in the 1-Wasserstein distance, extending classical universal approximation theorems to the quantum-distribution setting. We additionally introduce a multimodal latent prior and a mixture-of-experts circuit architecture, and show empirically that the latent-conditioned parameterization alleviates the barren plateau problem during optimization, a behavior for which we provide rigorous partial guarantees. Numerical experiments validate the framework on a synthetic multi-cluster ensemble of mixed quantum states and on a QM9-derived ensemble of 3-D molecular structures. In these tasks, LPQC outperforms recent quantum generative baselines and matches the generation quality of a classical neural-network baseline, while requiring an output dimension that grows only linearly with the number of qubits rather than exponentially. By leveraging classical expressivity in the latent space, LPQCs offer a tractable route to quantum generative modeling.