An End-to-End Automated Pipeline for Controllable Crack Data Synthesis

Reliable crack detection and segmentation are vital for structural health monitoring, yet the scarcity of well-annotated data constitutes a major challenge. To address this limitation, we propose a novel context-aware generative framework designed to synthesize realistic crack growth patterns for data augmentation. Unlike existing methods that primarily manipulate textures or background content, CrackForward explicitly models crack morphology by combining directional crack elongation with learned thickening and branching. Our framework integrates two key innovations: (i) a contextually guided crack expansion module, which uses local directional cues and adaptive random walk to simulate realistic propagation paths; and (ii) a two-stage U-Net-style generator that learns to reproduce spatially varying crack characteristics such as thickness, branching, and growth. Experimental results show that the generated samples preserve target-stage saturation and thickness characteristics and improve the performance of several crack segmentation architectures. These results indicate that structure-aware synthetic crack generation can provide more informative training data than conventional augmentation alone.

Substation meters play a critical role in monitoring and ensuring the stable operation of power grids, yet their detection of cracks and other physical defects is often hampered by a severe scarcity of annotated samples. To address this few-shot generation challenge, we propose a novel framework that integrates Knowledge Embedding and Hypernetwork-Guided Conditional Control into a Stable Diffusion pipeline, enabling realistic and controllable synthesis of defect images from limited data. First, we bridge the substantial domain gap between natural-image pre-trained models and industrial equipment by fine-tuning a Stable Diffusion backbone using DreamBooth-style knowledge embedding. This process encodes the unique structural and textural priors of substation meters, ensuring generated images retain authentic meter characteristics. Second, we introduce a geometric crack modeling module that parameterizes defect attributes--such as location, length, curvature, and branching pattern--to produce spatially constrained control maps. These maps provide precise, pixel-level guidance during generation. Third, we design a lightweight hypernetwork that dynamically modulates the denoising process of the diffusion model in response to the control maps and high-level defect descriptors, achieving a flexible balance between generation fidelity and controllability. Extensive experiments on a real-world substation meter dataset demonstrate that our method substantially outperforms existing augmentation and generation baselines. It reduces Frechet Inception Distance (FID) by 32.7%, increases diversity metrics, and--most importantly--boosts the mAP of a downstream defect detector by 15.3% when trained on augmented data. The framework offers a practical, high-quality data synthesis solution for industrial inspection systems where defect samples are rare.

Cracks are a critical indicator of building health, and early stage identification is fundamental to prevent harmful damages. Advances in deep learning (DL), particularly convolutional neural networks (CNNs), have enabled scalable solutions for automated crack detection. However, CNN performance strongly depends on the availability of large and diverse datasets, which is particularly challenging for complex surfaces such as masonry. Collecting sufficient real data is time-consuming, while publicly available datasets may not be adequate. To address this limitation, we explored generating synthetic crack data, which complements real data and improves training effectiveness. The real dataset consists of masonry crack images collected from buildings in Bologna and surrounding areas. In contrast, the synthetic dataset was generated using a crack overlay tool that adds cracks to background images in a controlled orientation and placement. The real dataset was used to train several DL architectures, to identify the best-performing model (InceptionV4) employed for experiments with generated data. Six training scenarios were tested in InceptionV4 by varying the ratio of real and synthetic data, with evaluation performed on a test set composed of real images using the F1-score and mean Intersection over Union (mIoU) metrics. Results show that training on synthetic data plus a modest addition of 20% real data achieves results comparable to training on real data only. Moreover, the 20/80 scenario (synthetic/real) achieved an 76% F1-score and 80% mean IoU, outperforming the real-only case. As can be seen, the method demonstrates the potential of synthetic data to reduce collection efforts while enhancing crack detection accuracy.