A Research Prototype for Closed-Loop Generative Design of Customized Foot Orthoses via Semantic-Physics Alignment

This paper investigates whether magnetic plantar sensing can be embedded directly inside the load-bearing compliant element of a low-cost semi-active prosthetic foot. We present a prototype integrating a sensorised 3D-printed lattice footplate, a servo-adjustable hydraulic damper, and a reduced-order ankle model. The damper is experimentally characterised to relate adjustment angle to damping coefficient. Controlled compression tests show tunable lattice stiffness, while cyclic normal loading shows that the embedded sensor tracks the testing-machine reference force, supporting plantar-force estimation without an external insole layer. Static-posture trials under approximately body-weight loading show that forefoot and rearfoot loading distributions are separable across four prescribed stance configurations, providing a preliminary check of the sensing pipeline. A feedforward damping schedule approximates the dorsiflexion trend of a reference ankle trajectory through early-to-mid stance, while exposing the expected limitation that a purely dissipative mechanism cannot generate active push-off. Together, these results demonstrate that sensing can be embedded inside the load-bearing compliant element of a prosthetic foot and used to drive semi-active damping.

High-fidelity computational fluid dynamics (CFD) is widely used for thermal-fluid design, but repeated CFD solves remain expensive for design optimization, uncertainty analysis, and digital-twin workflows. Recently, our team has demonstrated that a proper orthogonal decomposition and neural-network (POD-NN) surrogate can predict two-dimensional thermal fields in an electronics-cooling cold plate with large inference speedups while preserving physically interpretable modal structure. Reproducing and extending such workflows, however, typically requires custom scripts for parameter sampling, Fluent automation, data extraction, reduced-order model construction, neural-network training, validation, and prediction. This paper introduces CFDTwin, an open-source Python package and optional desktop graphical user interface (GUI) that packages these steps into a reusable workflow for ANSYS Fluent simulations. CFDTwin allows users to define simulation inputs and output quantities, generate design-of-experiments samples, run and resume Fluent batch simulations, train POD-NN surrogate models for scalar, surface-field, and cell-zone outputs, inspect validation metrics, and evaluate trained models at new design points without re-running Fluent. The same workflow is exposed through a scriptable Python API and a GUI, supporting reproducible studies, user-facing model validation, and automated design exploration. CFDTwin extends the prior POD-NN modeling study from a case-specific research implementation to a reusable research-software platform for CFD surrogate modeling and digital-twin development.

Computer-aided design (CAD) is the backbone of modern industrial design, yet learned CAD generators still fall short of real engineering pipelines: they neither iterate like engineers nor evaluate what engineering requires. Prior work has treated CAD generation as two disjoint steps, part synthesis and assembly, where the former is graded by proximity to a gold reference and the latter, when handled at all, is reduced to a separate constraint solving step. In this work, we introduce a more industry-native task formulation that requires a model to produce a fully assembled multi-part STEP file from a free-form engineering brief, which is then validated via finite element analysis (FEA). FEA validation reveals that Codex (GPT-5.5) and Claude Code (Opus-4.7) agents do not produce a single strict-passing artifact in the main first-attempt sweep, with the best configuration meeting only about 20% of typed requirements on average. Moreover, we introduce two additional supervision signals, a novel text-only blueprint schema and a 21-view image renderer that aids the agent's visual inspection, that better align the generation loop with how engineers iterate in practice. On S2O and Fusion360, the same feedback tools improve geometric reconstruction, with GPT-5.5/xhigh rising from 0.444 to 0.592 Box-IoU on S2O and from 0.397 to 0.505 on Fusion360. Together these signals move CAD programs toward artifacts that are not only visually plausible but also checked against physical and structural requirements.