Integrated Laser Scanning and Image-Based Topology Optimization Techniques for Detection and Quantification of Visible and Subsurface Structural Defects

Internal voids are ubiquitous defects in manufactured structures, yet their characterization remains challenging because their geometry is hidden and can only be inferred indirectly from accessible measurements. Here we introduce \textit{GenVoid}, a physics-informed generative model-based framework for identifying internal voids in complex two- and three-dimensional solids from surface displacement measurements alone. By incorporating the governing mechanics into a generative inference framework, \textit{GenVoid} enables void identification across linear elastic, hyperelastic and plastic material behaviours and accommodates complex two- and three-dimensional structural geometries. Importantly, the framework explicitly accounts for uncertainty and noise in displacement measurements, producing probabilistic reconstructions of internal void geometry rather than a single deterministic estimate. We demonstrate the approach using high-fidelity synthetic datasets and experimentally measured displacement fields obtained from in-situ mechanical experiments, establishing its ability to infer hidden voids from realistic displacement measurements. To quantify the fundamental limits of such inference, we further introduce an observability measure that characterizes the sensitivity of boundary measurements to localized stiffness perturbations within the interior under an ensemble of applied loads. This framework provides a direct connection between defect location, sensor configuration and reconstruction fidelity, enabling systematic assessment of how the number and spatial distribution of boundary measurements govern void-identification accuracy. To this end, these results establish a physics-informed and uncertainty-aware approach for non-invasive characterization of hidden defects and provide a quantitative basis for designing measurement strategies for inverse problems in solid mechanics.

Steel surface defect segmentation is critical for industrial quality inspection, yet existing methods struggle with elongated, anisotropic defects such as cracks and scratches due to the isotropic receptive fields of standard convolutions and rigid sampling grids that cannot adapt to irregular defect boundaries. To address these limitations, we propose Strip-based Predictor for Deformable Convolutional Networks (SPDCN) with two key innovations. The \textbf{Fuzzy-enhanced Multi-scale Context Module (FMCM)} employs group-wise multi-branch convolutions with an intuitionistic fuzzy channel attention mechanism to adaptively capture multi-scale contextual information across varying defect sizes. The \textbf{Adaptive Direction-Aware Deformable Convolution (ADADC)} replaces the conventional offset predictor with decoupled horizontal and vertical strip convolutions, enabling the deformable sampling grid to anisotropically align with the principal orientation of elongated defects. Extensive experiments on public steel surface defect benchmarks demonstrate that SPDCN consistently outperforms state-of-the-art methods, achieving 89.60% mIoU on NEU-Seg with only 3.54M parameters. The source code is publicly available at https://github.com/DWlzm .

Digital twins provide a scalable and cost-effective complement to real-world testing for validating autonomous-driving and advanced driver-assistance system (ADAS) sensor pipelines. However, quantifying their fidelity remains challenging, particularly for 3D LiDAR point clouds, where conventional geometric metrics may overlook important structural discrepancies. We present a graph-based framework for evaluating the structural fidelity of simulated LiDAR point clouds against real-world scans. While scan-level metrics such as Chamfer distance capture point-wise geometric similarity, they do not explicitly represent connectivity, topology, or object-level organization. Our framework constructs graphs from real and simulated point clouds, applies Louvain community detection to identify spatially coherent subgraphs, and matches corresponding communities using centroid proximity. For each matched pair, we compute $r_λ$, a bounded graph-spectral metric motivated by Weyl's inequality, and compare it with density-aware Chamfer distance (CDC) as a geometric baseline. Controlled perturbation experiments demonstrate that $r_λ$ is invariant to rigid transformations and robust to sensor noise while remaining sensitive to structural deformation. We evaluate the framework on 50 paired real and simulated LiDAR scans acquired using a Velodyne VLP-32C sensor and CARLA, respectively. The dataset contains more than 1,000 matched communities across four representative classes: vehicles, vegetation, trees, and building walls. The results show that geometric and structural measures capture complementary aspects of simulation fidelity, supporting graph-spectral analysis as an additional diagnostic layer for validating digital twins in ADAS and autonomous-driving applications.