Data-Driven Forward and Inverse Modeling of V-Beam Thermal Sensors

Directed energy deposition (DED) produces complex thermo-mechanical responses that can lead to distortion and reduced dimensional accuracy of a manufactured part. Thermo-mechanical finite element simulations are widely used to estimate these effects, but their computational cost and the complexity of accurately capturing DED physics limit their use in design iteration and process optimization. This paper introduces FLARE (Field Prediction via Linear Affine Reconstruction in wEight-space), a data-efficient surrogate modeling framework for predicting post-cooling displacement fields in DED from geometric and process parameters. We develop a predefined-geometry DED simulation workflow using an open-source finite element framework and generate a dataset of simulations with varying geometry, laser power, and deposition velocity. Each simulation provides full-field displacement, stress, strain, and temperature data throughout the manufacturing process. FLARE encodes each simulation as an implicit neural field and regularizes the corresponding neural-network weights so that they follow the affine structure of the input parameter space. This enables prediction of unseen parameter combinations by reconstructing network weights through affine mixing of training examples. On this DED benchmark, the method shows improved accuracy compared to baseline methods in both in-distribution and extrapolation settings. Although the present study focuses on DED displacement prediction, the proposed affine weight-space reconstruction framework offers a promising approach for data-efficient surrogate modeling of physical fields.

Real-time monitoring of the temperature distribution within components and sub-structures is a challenging topic in many systems due to restrictions on feasible sensor locations. While machine learning (ML) proves a versatile tool in many applications, its adoption for high-resolution thermal monitoring is hindered by the availability of high-quality datasets for training. In this work, we propose a novel approach for generating datasets for industrial applications based on randomized physics-based simulations. We demonstrate the approach in a proof-of-concept hardware setup: A neural network (NN) trained only on such a synthetic dataset, is used to reconstruct the internal temperature field from sparse sensors embedded in the hardware. The NN-based reconstructions do not only outperform Kriging in robustness but also enable real-time inference, making the method suitable for online monitoring of otherwise unobservable thermal states.

Inferring latent physical properties from sensory observations is a fundamental challenge in machine perception. Among available sensing modalities, thermal imaging is particularly promising because temperature evolution is directly governed by heat-transfer physics and therefore encodes information about underlying thermophysical properties of a scene. Recovering spatially resolved thermophysical properties from thermal observations could transform applications ranging from digital twins and infrastructure monitoring to robotics and scientific imaging. However, existing thermal scene reconstruction methods can recover temperature fields in complex 3D environments without identifying the thermophyiscal properties that govern thermal evolution, whereas inverse methods provide physically interpretable parameter estimation but typically rely on simplified geometries and controlled experimental conditions. Here we introduce ThermoField, a framework that unifies thermal scene reconstruction and thermophysical parameter estimation through differentiable heat-transfer simulation. The proposed framework represents these quantities as spatially varying neural fields and constrains them through scene geometry, governing heat-transfer physics, and temporal thermal observations. We demonstrate that ThermoField jointly reconstructs geometry, estimates spatially varying thermal diffusivity, and predicts thermal evolution under previously unseen environmental conditions. By integrating neural scene representations with differentiable heat-transfer solver, the framework enables physically interpretable parameter inference in complex 3D scenes. Our results establish a bridge between thermal scene reconstruction and inverse heat-transfer analysis, providing a unified approach for geometry reconstruction, thermophysical property estimation, and predictive thermal simulation from thermal observations.