Physics-Informed Machine Learning Under Small-Data Constraints: Lessons from Abrasive Waterjet Milling

Physics-informed machine learning (PIML) integrates mechanistic knowledge, typically in the form of partial differential equations (PDE), into data-driven models. Despite strong empirical performance, its statistical generalisation properties remain poorly understood, particularly in the regression setting with unbounded losses. Existing analyses rely on approximation or stability arguments and do not fully capture how physical structure influences generalisation from finite data. In this work, we develop a PAC-Bayesian framework for PIML that provides high-probability generalisation guarantees in the presence of unbounded losses. We adopt a multi-task perspective that jointly treats data fidelity, PDE residuals, initial and boundary conditions, avoiding the looseness induced by standard union-bound approaches. Our analysis leverages the structure of physics-informed objectives to derive novel bounds where the complexity scales with input-gradient norms of the losses, revealing a direct link between physical regularity and generalisation. We instantiate this framework under Sobolev and Poincaré-type assumptions, yielding two classes of bounds that trade off statistical complexity and smoothness in different regimes. Building on these results, we propose a self-bounding-aware learning algorithm that directly optimises tractable surrogates of the derived bounds, along with a practical procedure to estimate the associated constants in realistic settings. Empirical evaluations on standard PDE benchmarks demonstrate that our bounds are non-vacuous, significantly tighter than union-bound baselines, and can be effectively minimised during training. Overall, our results provide a principled statistical foundation for the generalisation of physics-informed models.

Physics-informed machine learning is often assessed by curve error, although engineering use depends on downstream decisions: ranking candidates, avoiding infeasible designs and limiting regret. We introduce pinn-gym, an open benchmark for material-conditioned lattice design that couples a transparent reduced-order crush-and-impact oracle with five printable polymer cards, dimensionless force-response targets and a protocol spanning curve fidelity, physical admissibility, top-k retrieval and mass regret. Across per-material, pooled and cross-material settings, low nRMSE is frequently insufficient to identify useful design selections. Physics-informed losses alter trade-offs rather than monotonically improving all metrics, and dimensionless conditioning improves comparability without making transfer symmetric. The benchmark is not a certified material model; within the released oracle, candidate generator and material cards, pinn-gym provides a reproducible testbed for evaluating PIML surrogates as decision systems rather than curve predictors alone.

Reliable prediction of crystallographic texture in laser powder bed fusion is critical for linking process conditions with anisotropic response and for qualification. However, black-box models may fail under shift and cannot distinguish weak data support from loss of physical validity. This study develops a two-stage physics-based model for <001> || BD (build direction) texture in Inconel 718. Stage 1 maps process variables to melting mode and melt pool geometry. Stage 2 predicts texture by combining an empirical physics model with a random-forest residual model. A k-nearest-neighbor weight attenuates residual corrections for poorly supported queries, while a study-specific areal beam-power-density criterion withholds predictions outside the adopted conduction envelope. Conformal intervals are evaluated on the retained physics-valid set, and SHAP and Sobol analyses assess residual sensitivity. Under a controlled leave-one-defocus-out evaluation, the physics anchor achieved R^2 = 0.778, against -0.001 for the black-box model and 0.750 for the gated hybrid. Under leave-one-group-out cross-validation, the gated hybrid reached R^2 = 0.592 against 0.538 for the black-box model. Retained-set coverage was 92.9% at a mean full width of 3.65 multiples of a uniform distribution (MUD) under grouped cross-validation and 100% at a width of 3.21 MUD under transfer to a withheld +80 mm defocus regime. An illustrative mapping produced a retained BD elastic-modulus span of 127-187 GPa. On nine conditions from a separately built sample set, the framework withheld three, attenuated three, and matched the measured ordering for the rest. Separating data applicability, physics validity, and predictive uncertainty into distinct decisions lets the framework transfer where an unconstrained model does not, and withhold predictions where no model class performs adequately.