Scalable Defect Detection

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.

Flat roofs are among the most influential components of the building envelope, governing both structural performance and thermal efficiency, and thereby contributing directly to household energy consumption, carbon emissions, and long-term environmental sustainability. Timely detection of roof defects is essential for reducing heating and cooling losses, preventing moisture-driven degradation such as mold growth, and supporting national climate-change mitigation goals. This paper presents a real-time, Unmanned Aerial System (UAS)-based deep learning framework that autonomously detects defects using live imagery captured during dual-altitude aerial passes. The multi-resolution flight strategy is designed to aid the identification of both small, fine-scale defects and larger structural issues, enabling more comprehensive assessments. To meet the strict computational and power constraints of embedded UAS hardware, the proposed framework integrates a tile-based architecture with a lightweight Convolution Neural Network-Support Vector Machine (CNN-SVM) classifier designed for low-latency onboard inference. The final model-comprising five convolutional layers and four dense layers, the last a linear SVM head, achieved a mean test accuracy of $94.4\%$ ($95\%$ confidence interval $\pm0.4\%$ over three seeds) on a photo-level split ($43,383$ training, $3,869$ validation, and $2,540$ test tiled and augmented images), outperforming GoogLeNet ($89.2\%$) and AlexNet ($79.8\%$). Experimental evaluations using real UAS imagery collected by onsite visits with DJI Matrice 350 RTK drone demonstrate that the system supports rapid, repeatable, and safe roof inspections while reducing human risk, lowering operational costs, and enabling more sustainable building maintenance.

Automated classification of sewer defects is essential for infrastructure condition assessment and maintenance decision-making, but existing deep learning methods struggle to balance classification accuracy and computational complexity in large-scale multi-label scenarios. This study develops Sewer-Transformer-ML, a hierarchical vision Transformer with multi-level feature fusion, together with two lightweight architectures, Sewer-MobileNet-ML and Sewer-Mobile-TransNet, for resource-constrained inspection scenarios. On the Sewer-ML test set, Sewer-Transformer-ML-Base achieved an $F2_{\text{CIW}}$ of 65.68% and an $F1_{\text{Normal}}$ of 92.68%, ranking first on the public leaderboard and exceeding the second-ranked method by 7.6 percentage points in $F2_{\text{CIW}}$. Sewer-MobileNet-ML achieved an $F2_{\text{CIW}}$ of 65.73% with only 17 M parameters, representing an approximately 95% parameter reduction relative to the base model. Under the standard Sewer-Capsule data split, Sewer-Mobile-TransNet achieved 96.43% classification accuracy. When the training set was reduced to 1,177 images, pretraining on Sewer-ML consistently improved model performance. Ablation experiments further showed that direct concatenation was more effective for Transformer features, whereas attention-based fusion better supported multiscale CNN features. These findings provide a computational basis for automated sewer inspection, lightweight model design, and adaptation across civil infrastructure inspection platforms.

A research idea may be novel, coherent, and scientifically plausible, yet its proposed method may remain insufficiently specified for faithful implementation. We study the codification readiness of implementation-facing research-method specifications, defined by whether they provide sufficient methodological information for a competent implementer or coding agent to construct the intended method without unsupported assumptions. We construct evidence-grounded specifications and their supported resolutions from papers, codebases, issue threads, and reproduction artifacts. We introduce IdeaAMBIG, a benchmark of 660 evidence-grounded instances: 163 real-world gaps from reproducibility reports and GitHub issues, and 497 controlled synthetic gaps injected into codification-ready references. IdeaAMBIG evaluates three capabilities: codification-readiness assessment, defect localization, and clarification action generation. Defect localization receives only the specification, whereas clarification additionally receives the annotated defect. Across 13 LLMs, the best model achieves 9.6% Macro Defect Recovery Rate on real-world instances but 80.6% Macro Clarification Action Success Rate when given the defect. In an oracle study, supplying the gold resolution raises the downstream codification-ready rate from 14% to 98%. Across all evaluated models, defect localization is the main bottleneck, with stronger clarification given the defect.

Product families in large product catalogs suffer from inconsistencies such as duplicates and unit mismatches that degrade customer experience. Detecting these requires reasoning over multiple error types across lengthy product listings, where LLM classification quality degrades due to long-context limitations. We address this by decomposing detection into focused sub-tasks that reduce context and isolate error types, improving F1 from 52% to 87%. For scalable deployment, we introduce Positional Task Conditioning (PTC), which distills this capability into a single smaller model by reinforcing task identity at structural prompt boundaries. PTC outperforms rationale-based distillation across five models and two architecture families, achieving within 1.79% F1 of the frontier at upto 98% lower cost. Our system is deployed across multiple countries processing 10+ million product families.

Industrial inspection pipelines often restore a measured image before a detector acts on it, yet restoration can suppress detector-supported defect structure or create clean-region activations. We formulate restoration as a selective action problem over the measured display, five restored candidates, and review. SafeRestore ranks candidates with action-specific fitted scores, chooses a gate on threshold-tuning data, and evaluates the fixed gate on a disjoint certification sample with two one-sided exact binomial bounds: one for the positive-conditional evidence-loss incident rate and one for the all-accepted excess-activation incident rate. The guarantee is marginal for one policy fixed before its certification outcomes are observed, under an image-level i.i.d. working model. In a retrospective split-sample study of 4,591 public Carinthia-S images, the protocol yields auditable risk-coverage behavior. The primary all-action policy passes in one of five training repetitions (12.0% +/- 26.9% pass-gated test coverage when failures count as zero), whereas fixed bicubic and reduced-complexity variants pass more often. On reserved morphologies, evidence-loss incidence rises to 81.1-90.3%, and KolektorSDD lacks both detector competence and enough positive certification images for the stated target. The contribution is therefore an auditable, detector-relative framework for deciding when a transformed image may be returned automatically and when review remains necessary -- not a claim that adaptive routing outperforms simpler policies on the present evidence.

Reliable characterization of structural defects requires methods capable of resolving both directly observable surface damage and damage that is not visible from the inspected surface. This study presents two complementary non-contact, vision-based approaches for the detection and quantitative characterization of defects in structural components. The first approach employs high-resolution laser scanning to generate three-dimensional (3D) point clouds of damaged steel specimens. Comparative processing of measured and reference point clouds is used to localize damaged regions, quantify geometric loss, and transfer the measured defect geometry to a finite element representation. The second approach combines full-field surface deformation measurements obtained using three-dimensional digital image correlation (3D-DIC) with finite element model updating and topology optimization. In this inverse framework, measured surface response is used to infer subsurface abnormalities through their influence on the spatial distribution of structural response. Experimental steel-beam specimens containing controlled smooth defects and randomly distributed defects are used to evaluate the approaches. Comparisons with milling-based ground-truth measurements demonstrate that both methods can identify and quantify defect geometry, while providing complementary information for visible and subsurface damage assessment. The combined framework establishes a pathway toward high-fidelity, non-contact structural condition assessment and model updating for components with complex and irregular damage.

Promptable segmentation foundation models such as SAM3 accept an open-vocabulary text concept and return every instance matching it, but adapting them to a specialized domain by full fine-tuning is computationally prohibitive for the organizations that would benefit most. This study applies Low-Rank Adaptation (LoRA) to SAM3 for multi-class structural defect segmentation and examines both how such a model can be supervised from conventional annotation and whether the resulting efficiency gain transfers across datasets. Two contributions are methodological. First, we describe a supervision procedure that trains a concept-promptable model directly from COCO-style class-labeled instance segmentation by using the category name itself as the prompt, requiring no prompt templates, no synonym expansion, and no learned class embeddings. Second, we identify and mitigate a failure mode specific to this setting: because a conventional annotation file yields positive prompts exclusively, the model's presence prediction decouples from the text condition and degenerates into responding to any prompt, a collapse that is invisible to every metric computed on positive prompts alone. Exhaustive hard-negative prompting, in which every dataset category absent from an image is issued as a zero-detection query, addresses this at no annotation cost. Two adapter placements were compared under an identical protocol, updating 0.121% and 1.341% of model parameters. On a purpose-built tunnel lining dataset, pixel intersection-over-union improved from 0.017 to 0.338 and instance-level recall from 0.375 to 0.672; on the independent public Structural Defects Dataset, from 0.017 to 0.855 and from 0.574 to 1.000. Improvements were directionally consistent across ten metrics on both datasets, and the largest per-category gains occurred precisely where zero-shot competence was absent.

In semiconductor manufacturing, defect analysis is essential, but manual inspection cannot scale. However, existing automated inspection methods remain insufficient for root-cause analysis and process optimization. To this end, we present SePArate, a weakly supervised wafer defect segmentation method. SePArate enables pixel-level separation of patterns by leveraging only image-level annotations. It consists of a three-phase training: encoder pretraining, knowledge transfer to learn spatial cues, and training on synthetic mixed-defect data for accurate segmentation. Experiments demonstrate that SePArate outperforms the baselines.

This paper addresses the challenge of multi-label defect classification in electroluminescence (EL) images of photovoltaic (PV) cells. Training models on images where multiple defects co-occur creates learning ambiguity, making it difficult to disentangle visual features for specific defect types, a problem compounded by the scarcity of examples for individual classes. To tackle this, we introduce Generative Defect Isolation (GDI), utilizing the LaMa inpainting model with Fast Fourier Convolutions to remove selected defects and generate realistic, single-defect training samples. Extensive experiments on Vision Transformer (ViT-S, ViT-L) and EfficientNetV2-L architectures demonstrate that GDI significantly outperforms baselines. The performance gains are most pronounced in low-data scenarios; class-wise analysis shows substantial improvements, boosting the F1-Score for rare defect classes by up to 63.6%. Furthermore, GDI effectively resolves learning ambiguity from co-occurring defects, yielding a 26% reduction in such co-occurring classification errors. Our work establishes GDI as an effective method for maximizing the value of existing segmentation datasets and sets a new performance benchmark for multi-label classification in this domain.

Vehicle-mounted road cameras are vulnerable to motion blur, defocus, poor illumination, and noise, which can erase thin cracks and pothole boundaries needed by road defect detectors. This paper presents RMR-Net, a compact task-aware restoration front end that estimates degradation evidence from the image, optionally fuses it with existing corruption context/parameters, conditions lightweight restoration blocks, and returns high-frequency pavement detail through a bounded residual path. The experimental scope is deliberately controlled: the conditioning information used on the Image and Vision Computing New Zealand (IVCNZ) pothole dataset and the Road Damage Dataset: Potholes, Cracks and Manholes (PCM) consists of saved synthetic-generator parameters, not measured vehicle telemetry. A clean-trained, frozen YOLO11s detector evaluates every image source. Across eight held-out degradation conditions, RMR-Net obtains the highest mAP50 in seven, including 0.140-0.427 for IVCNZ motion blur and 0.060-0.233 for PCM defocus. A compact ablation identifies the bounded detail path as the largest local contributor, while degradation conditioning and detector-aware stability terms provide complementary guidance.

This paper presents RobustDefect-LLM, an industrial surface-defect inspection framework integrating deep-learning classification, operator-facing visual evidence, confidence-aware decision support, controlled AI-assisted reporting, traceable storage, and mobile interaction in a unified quality-control workflow. Here, robustness-aware denotes explicit evaluation under controlled image degradation and confidence-aware review routing, not an intrinsic robustness guarantee. Four transfer-learning-based convolutional neural networks, ResNet50, EfficientNet-B0, DenseNet121, and MobileNetV3-Large, were evaluated on 1,799 images from the six-class NEU-DET dataset using fixed training, validation, and held-out in-domain test partitions. MobileNetV3-Large achieved the highest numerical test accuracy (99.26%) and macro F1-score (0.9926), with a bootstrap 95% accuracy CI of 0.9815-1.0000. An exact paired McNemar test found no significant difference from DenseNet121 (p = 1.000). The selected model averaged 0.060 s per CPU forward pass (16.66 FPS). Under combined synthetic degradation, accuracy fell to 87.78% at mild intensity and below 40% at stronger intensities, revealing sensitivity to severe image-quality deterioration. Grad-CAM supplied visual evidence, while predictions with confidence below 0.90 or a top-2 margin below 0.10 were routed to HUMAN REVIEW. This conservative policy provided 12.22% automatic coverage and 100% observed selective accuracy among 33 eligible cases (95% CI: 89.43%-100.00%), while routing both observed classification errors to review. Under nominal controlled conditions, all 100 generated reports passed deterministic consistency checks, with a mean latency of 1.66 s. Results support the feasibility of the integrated workflow while emphasizing the need for calibration, repeated evaluation, and real-world industrial validation.

Reliable identification of railway wheel defects is important for safety and maintenance. This study develops a machine-learning-based diagnostic framework for multi-class defect identification using passive air-coupled ultrasonic acoustic emission signals. Data were collected from eleven full-scale railway wheelsets representing nine health states. Time- and frequency-domain features were evaluated using Kruskal-Wallis statistical testing and mutual-information analysis to identify the most discriminative indicators. A Random Forest classifier was then trained using the selected features with stratified 5-fold cross-validation. The model achieved a balanced accuracy of approximately 0.66 and a Macro-F1 score of 0.65 across the nine classes. Decay rate, kurtosis, skewness, and envelope low-frequency power emerged as the most influential features, while a compact subset of features retained most of the classification performance. The results demonstrate the feasibility of combining passive ultrasonic sensing, statistical feature selection, and supervised machine learning for non-contact railway wheel defect classification and provide a foundation for future field-deployable inspection systems.

Automated anomaly detection methods often report strong performance on curated academic benchmarks, but their behavior under real-world industrial conditions is less clear. In this work, we evaluate 19 unsupervised anomaly detection models on the BowTie dataset, a challenging manufacturing dataset with reflective surfaces, subtle defects, and profile-specific variation. In contrast to benchmark results, we observe that model performance is less stable than typically reported on standard benchmarks such as MVTec AD, highly sensitive to preprocessing, and inconsistent across conditions, with no single approach emerging as uniformly robust; a consensus audit further indicates that nominal-data quality affects deployment. Motivated by these findings, we developed and initially deployed a unified human-in-the-loop framework for manufactured-part inspection that combines image annotation, AI-assisted defect detection, and an integrated validation engine, replacing a prior manual visual inspection and documentation workflow. The system supports heatmap-guided defect review, SAM-refined candidate regions for inspector acceptance, rejection, or boundary adjustment, mask evaluation where annotations exist, and review history for inspector consistency and onboarding. Together, the results highlight the gap between benchmark performance and deployment reality, and provide a practical framework for addressing it.

Wind turbine blade defect detection remains highly challenging in real-world inspection scenarios due to limited on-site data and the subtle visual characteristics of defects. In practice, blade defects are often small-scale, low-contrast, and difficult to distinguish from complex backgrounds, which significantly limits the robustness of existing detectors. To address these challenges, we propose BladeYOLO, a defect detection framework for wind turbine blades. Specifically, we integrate a Vision Transformer (ViT) backbone initialized with DINOv3 self-supervised pre-trained weights into YOLOv12-L, enabling the transfer of large-scale generic visual priors to blade defect detection and improving feature representation under limited training annotations. To enhance the perception of subtle defects, we further develop a Mamba-guided Weak-Defect Enhancement module, which consists of a Detail-Enhanced Multi-scale Branch for preserving high-frequency structural cues and a Cross-Mamba module for progressively propagating high-level semantic guidance to shallow features. In addition, we introduce a lightweight Style-Injector module that captures environment-related style information via Fourier decomposition and injects it into selected ViT self-attention layers, thereby improving robustness against environment-induced appearance variations. Extensive experiments demonstrate that BladeYOLO achieves superior performance on the WTBlade-Defect dataset, with additional annotation-budget experiments showing its favorable performance under reduced training annotations. Evaluation on the public Wind Surface Defect dataset further provides supportive evidence for the cross-dataset robustness of BladeYOLO. In particular, on this public dataset, BladeYOLO outperforms the best competing method by 3.5% in mAP$_{50}$ and 2.5% in mAP$_{50-95}$.

While automated defect detection such as the detection of surface scratched is an important aspect in industrial quality control, the scarcity of annotated defect data make this task challenging. This paper presents a procedural rendering pipeline that generates large-scale annotated synthetic training data using BlenderProc, with configurable material appearance, camera modes, and domain randomization, producing automatic COCO-format annotations. To show the potential of our approach, we evaluate four training strategies, namely synthetic-only, real-only, mixed, and fine-tuning from synthetic weights, across two objects with different material properties and three lightweight edge-deployable detectors, YOLOX, YOLO26, and LW-DETR. Our evaluation show that fine-tuning from synthetic weights consistently outperforms real-only training, and that mixed training effectively recovers performance under scarce real-data conditions, with findings validated across both convolutional and transformer-based architectures. The proposed approach enables scalable defect detection without the burden of large real annotated datasets, making it practical for on-device industrial inspection. The pipeline scripts, 3D model, and both synthetic and real annotated scratch datasets for a glossy toy Ferrari car will be made available through the project website upon acceptance.

Quality control in printing, particularly in rotogravure printing, still depends on slow, costly, and subjective manual inspection. Automated surface defect detection is critical for maintaining high-quality standards in rotogravure printing. Deep learning models give prospects for automation. However, training robust deep learning models, such as YOLO or Vision Transformers, is heavily hindered by the extreme scarcity of real-world industrial defects images. To overcome this limitation, this paper introduces a novel synthetic data generation framework tailored for rotogravure printing quality control. The proposed pipeline automatically generates high-fidelity images of specific printing defects (creases, streaks, misregistration, etc.) and outputs corresponding bounding boxes and annotations. To validate the framework, a synthetic dataset of 7533 images was generated and used to train the state-of-the-art object-detection model RFDETR. Experimental results demonstrate that the model trained on our synthetic data achieves a Mean Average Precision (mAP) of 80.9% on real industrial testing samples. This framework provides a zero-cost, rapid-deployment solution for automating defect inspection in printing lines without requiring massive manual data collection.

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 .

Automated visual inspection of steel surface defects is a recurring quality control task in which labeled defect data is scarce and costly to obtain, while unlabeled surface images are abundant, which motivates self supervised methods that learn useful representations without class labels. A Transformer based Masked Autoencoder is used here to learn representations of steel surface defects for unsupervised grouping. During pretraining, 75% of the input image patches are randomly masked, and a lightweight decoder reconstructs the masked regions from the visible 25%. The encoder is trained jointly with an auxiliary defect localization objective, used only as a training signal and not evaluated as a detector. The decoder reaches a structural similarity score of 0.92 and a mean squared error of 0.47. Features from the pretrained encoder are then clustered using UMAP for dimensionality reduction and Agglomerative clustering, reaching a Hungarian matched accuracy of 91.3% against the six known defect categories.

Few-shot industrial defect detection remains difficult for standard supervised detectors, which achieve poor performance on boundary-dominated industrial defects. This paper proposes rough path signature-guided geometry augmentation (RPS-GA), a geometry-aware approach in which Canny edge contours are treated as ordered planar paths whose truncated second-order signature responses, especially the antisymmetric Lévy-area term, are aggregated into a spatial map that highlights boundary-related structure through two fusion operators, SIG-AUG and SGAA. The approach is evaluated on NEU-DET and PCB-Defect under a few-shot protocol with 5, 10, 20, or 50 labeled images per class, using an unmodified YOLOv8n detector throughout. Compared with the baseline, RPS-GA delivers large gains when supervision is limited, although the margin shrinks as more labels become available. On NEU-DET, SIG-AUG raises 10-shot mAP@0.5 from 0.341 to 0.583, whereas on PCB-Defect, SGAA improves 10-shot mAP@0.5 from 0.086 to 0.299 and yields usable detection at 5-shot where the baseline fails entirely. These trends are confirmed by multi-seed evaluation across independent random partitions. Overall, the results indicate that second-order path-signature geometry offers a practical way to strengthen few-shot industrial defect detection without meta-learning or detector redesign.

Surface scratch defects in semiconductor manufacturing pose significant challenges due to their irregular shapes, low contrast, and varying scales. Traditional inspection methods often struggle to detect such defects reliably, especially in complex imaging scenarios. While deep learning approaches based on Convolutional Neural Networks (CNNs) have improved accuracy, they often fail to capture fine-grained edge details. To address these limitations, we propose ScratNet, a novel end-to-end scratch segmentation framework that integrates a modified Swin Transformer backbone with a tailored decoder. The decoder incorporates a Multi-Scale Dilated Aggregation (MDA) module to capture both local and global context, a Stem Integration Module (SIM) to restore spatial detail, and a Precision Refinement (PR) branch that enhances boundary sharpness using anisotropic convolutions. Through this stage-adaptive feature aggregation and boundary-aware refinement, ScratNet achieves superior accuracy on thin and irregular defects. Extensive experiments demonstrate that ScratNet consistently outperforms existing methods, providing a scalable and robust solution for automated scratch inspection in high-precision manufacturing.

This paper presents the IEEE International Conference on Multimedia and Expo (ICME) 2026 Grand Challenge on Cross-Scenario Defect Detection and Fine-Grained Severity Grading for High-Precision Manufacturing. The challenge is motivated by two key limitations of existing industrial defect inspection systems: (1) current deep learning-based methods often suffer significant performance degradation when deployed in unseen production scenarios, and (2) most benchmarks neglect severity-aware assessment, which is critical for risk control and yield optimization. To address these limitations, we design two complementary tracks: Track 1 (Cross-Scenario Defect Detection) targets accurate defect detection, localization, and classification across diverse unseen production environments; Track 2 (Fine-Grained Severity Grading) requires assigning each detected defect an industry-standard severity level, including Acceptable, Marginal NG, NG, and Gross NG. We construct a large-scale industrial dataset of high-resolution microscopic images spanning seven representative defect categories, comprising over 3,800 images with pixel-level instance annotations for Track 1 and over 2,600 images with severity-grade labels for Track 2. The challenge attracted 86 registered participants with 130 submissions; during the final testing phase, 21 teams submitted results and 12 teams provided models with technical reports. The resulting benchmark, together with the diverse and effective solutions contributed by participating teams, sets a new standard for industrial defect analysis research.

To address data overload and inefficient shape-level annotation in robotic visual inspection, this paper proposes a hardware-software integrated optoelectronic architecture. A non-imaging, low-data paradigm is established to minimize annotation dependency. First, a sensor-in-the-loop strategy reconfigures a Digital Micromirror Device (DMD) as a physical optical convolutional layer, enabling photonic-domain feature extraction that unifies sensing hardware and processing software. To suppress data volume at the source, a block-based compressed sensing strategy encodes spatial information into low-dimensional temporal signals, drastically reducing redundancy. Subsequently, to bypass laborious manual defect shape annotation, natural language descriptions guide the network to align with highly generalizable features from Contrastive Language-Image Pre-training (CLIP), steering the attention maps of the optoelectronic neural network toward defect shapes. Furthermore, a Localization Accuracy for Attention (LAA) metric is proposed to quantify shape-level defect localization performance. Experiments on transparent material defect detection validate the system's effectiveness. Parametric analysis reveals how measurement matrices, compression ratios, and block sizes affect accuracy. Results show that, compared to traditional imaging, the proposed architecture maintains equivalent accuracy while reducing data volume by 90% for Vision Transformers and computational workload by 60% for Convolutional Neural Networks. This low-data paradigm offers an efficient solution for industrial automation scenarios involving massive data streams, high acquisition costs, or constrained edge resources.

Remanufacturing large white goods is essential for a circular economy, yet visual quality assessment remains a manual bottleneck for training and pricing. Conventional detection methods require extensive annotation and struggle with small defects in high-resolution multi-view data. We present a multi-view framework based on Deformable-DETR for automated quality scoring that aggregates information across redundant views to extract fine-grained features. To enhance robustness with limited labels, we employ self-supervised pretraining followed by supervised fine-tuning on expert-annotated scores. Additionally, a linear projection over frozen feature maps identifies regions of interest to explain model decisions. Evaluated on an industrial multi-view dataset, our approach delivers precise quality assessments while reducing reliance on manual annotation and per-part customization, enabling scalable and transparent inspection for remanufacturing lines.

Artificial intelligence is rapidly advancing materials characterization, yet most applications in electron microscopy rely solely on image contrast, overlooking the chemical and experimental context that shapes image formation. This limitation makes defect classification inherently ambiguous, as similar contrasts can arise from different materials or imaging conditions. Here we develop a context-aware learning framework that integrates image-derived contrast with metadata describing composition, beam energy, and detector geometry. Using a systematically constructed dataset of ~55 million simulated patches spanning 576 cases across 96 doped monolayer transition-metal dichalcogenides, we show that conditioning on contextual variables transforms defect classification from an ill-posed image-only task into a well-posed, physically grounded problem. The framework achieves over 98% accuracy on simulations and near-human agreement on experimental data, with a 94% reduction in posterior entropy. By emphasizing contextual grounding over architectural complexity, this approach links experimental image contrast to the underlying chemical and imaging conditions, supporting physically grounded defect assignments and a general pathway toward multimodal AI models for autonomous materials characterization.

Semiconductor lithography inspection requires reliable detection of small pattern defects such as bridge, burr, pinch, and contamination. In this study, we propose a two-stage vision-language framework that combines initial defect detection with prediction refinement. In the first stage, Qwen3-VL is fine-tuned with LoRA as a vision-language adapter to predict defect counts, defect categories, and normalized bounding boxes from lithography images. However, direct fine-tuning may still produce common test-time errors, including false positives, missed defects, and incorrect defect types. To address this limitation, the second stage trains a refinement module using first-stage prediction failures and their corrected labels, allowing the model to review and revise initial outputs. By learning from cases where the initial adapter fails, the refinement process improves defect inference beyond single-stage fine-tuning.

Automated defect detection in high-voltage transmission-line insulators remains challenging due to severe class imbalance, large scale variation, and the small spatial extent of defect instances in Unmanned Aerial Vehicle (UAV) imagery. To address these challenges, this paper proposes AE-YOLO, an Attention-Guided AutoEncoder-Enhanced YOLO framework for robust insulator defect detection. The architecture integrates lightweight bottleneck autoencoders within a Feature Pyramid Network-Path Aggregation Network (FPN-PAN) neck. This preserves anomaly-sensitive information during multi-scale feature fusion. Convolutional Block Attention Modules (CBAM) are used throughout the backbone, enhancing feature discrimination and suppressing background interference. The framework also introduces a variance-maximizing autoencoder regularization strategy, which encourages diverse, defect-discriminative latent representations. The network trains using a unified objective that combines focal loss, Complete IoU (CIoU) loss, and autoencoder regularization to address foreground-background imbalance and improve localization accuracy. During inference, Weighted Boxes Fusion (WBF) combines predictions from YOLOv8, YOLOv10, and YOLO11. An autoencoder-guided confidence boosting mechanism improves sensitivity to rare defect categories. Experiments on the Insulator-Defect Detection dataset show that AE-YOLO with an EfficientNetV2 backbone achieves 95.10 percent mAP at 0.5, 96.40 percent precision, and 93.80 percent recall. This performance surpasses the strongest YOLO-family baseline by 5.0 points in mAP at 0.5 and 6.7 points in recall. These results confirm the effectiveness and adaptability of the framework. The model is a practical and scalable solution for UAV-based transmission-line inspection and defect monitoring.

Automated surface defect detection is critical for ensuring rigorous quality control in high-speed manufacturing environments. While deep learning models offer remarkable accuracy, deploying them on resource-constrained edge hardware without introducing significant latency remains a persistent challenge. This paper presents Industrial-YOLO, an edge-optimized framework built upon a fine-tuned YOLOv8 architecture specifically engineered for real-time industrial defect detection. We conduct a systematic benchmark utilizing the NEU surface defect database for steel sheets and the MVTec AD dataset, supplemented with custom automotive manufacturing extensions representing real-world structural anomalies (scratches, pits, and inclusions). To bridge the gap between algorithmic complexity and edge hardware constraints, target-specific optimizations are introduced via TensorRT and OpenVINO acceleration engines. Experimental results demonstrate that Industrial-YOLO achieves a high-velocity inference speed exceeding 120 FPS on the NVIDIA Jetson Orin platform while maintaining an exceptional mean Average Precision (mAP) of 98.5%. The proposed framework showcases highly robust, zero-latency performance when deployed directly onto an active automotive assembly line, offering a scalable blueprint for next-generation automated optical inspection (AOI) systems.

Printed circuit board (PCB) defect detection is an essential part of automated optical inspection (AOI); yet it remains challenging in practice because many defects are tiny, low-contrast, and embedded in dense circuit backgrounds. To address these issues, this paper presents a two-phase PCB defect detection framework that combines structure-guided mixed masked pretraining with spatial continuity regularization. In the pretraining stage, we design a sparse convolutional masked pretraining scheme to exploit unlabeled PCB images, where structure-guided mixed masking is used to construct informative masked inputs. The sparse convolutional reconstruction pipeline suppresses invalid responses from masked regions and enables the detector backbone to infer missing PCB structures from visible conductive patterns, thereby learning PCB structural priors. In the fine-tuning stage, the pretrained backbone is transferred to the downstream defect detection task. For the task, a spatial continuity regularization term is introduced during fine-tuning. This term constrains dispersed positive predictions assigned to the same defect instance and promotes more compact localization on elongated defect regions. Experiments on the DsPCBSD+ dataset show that the proposed method achieves 85.5% mAP0.5 and 52.3% mAP0.5:0.95, outperforming several strong baseline detectors. Ablation studies and qualitative results further confirm the effectiveness of the proposed framework for robust PCB defect detection in industrial AOI scenarios.

Metal surface defect detection is critical for maintaining product quality in industrial manufacturing. However, it faces significant challenges, including limited annotated data, difficulty in identifying subtle multi-scale defects, and poor generalization across diverse scenarios. To address these issues, this paper proposes a novel Contrastive Augmented Transformer (CAT) framework for robust defect detection. CAT employs a hierarchical Swin Transformer backbone and redesigns the feature pyramid network to effectively fuse low-level textures with high-level semantics, enabling precise modeling of subtle and multi-scale defect patterns. To enhance robustness under real-world noise conditions, we propose a domain-specific droplet augmentation algorithm. Furthermore, we incorporate a hard negative mining strategy into the contrastive loss to strengthen the model's discrimination ability in ambiguous defect regions. Experimental results on the KolektorSDD2 dataset demonstrate that CAT achieves a pixel-level AUROC of 99.54%, outperforming existing methods. In addition, CAT exhibits superior generalization and robustness on three unseen datasets, including KSDD1, MTD for tile defects, and MSDD for rail surface defects, demonstrating its potential for wide-scale industrial deployment.

Printed circuit board (PCB) defect detection is challenging because many defects are small and difficult to distinguish from complex background patterns. Most deep learning-based PCB inspection methods rely only on the inspected PCB image for defect detection, ignoring the defect-free reference image that encodes the expected layout of traces, pads, and other PCB structures. In this work, we propose RefDiffNet, a lightweight plug-and-play input enhancement block placed before the detector backbone to enhance the image before defect detection. RefDiffNet brings one proven idea from classical inspection into the deep learning era, using a defect-free reference image to reveal defects. RefDiffNet compares the defective image with the aligned reference, captures structural changes relative to the reference, and uses a lightweight encoder to output the original image with defective regions highlighted, thereby making the downstream detector's task easier. Results on HRIPCB and DeepPCB show that RefDiffNet consistently improves performance across detector families, including one-stage detectors from YOLOv8 to YOLOv26, the transformer-based RT-DETR, and the two-stage Faster R-CNN. It achieves up to 18% relative mAP50:95 gain with negligible overhead, introducing only 0.004 - 0.005M additional parameters and 0.7 - 0.8 GFLOPs, amounting to at most 0.25% of the parameter count of any evaluated detector. Results establish RefDiffNet as a lightweight, plug-and-play, detector-agnostic input enhancement module that substantially improves PCB defect detection with minimal computational cost.

Reliable identification of fracture origins in alumina matrix composite hip and knee implants is critical for quality assurance and patient safety, yet current fractographic workflows are time-consuming, partly subjective, and reliant on high-magnification scanning electron microscopy (SEM). We present an interpretable vision-transformer (ViT) workflow for automated classification of fracture causes in an alumina matrix composite (BIOLOX delta, CeramTec GmbH) widely used in total joint replacements. A dataset of 8,493 SEM images (50x-10,000x) was curated from five years of in-production burst and proof tests and annotated into three defect categories defined along the manufacturing chain: green body, hard machining, and material defects. Under severe class imbalance, the fine-tuned ViT reached an accuracy of 0.907 and a macro-F1 of 0.888 in stratified five-fold cross-validation, with a two-stage perceptual-hash/SSIM leakage audit confirming negligible specimen overlap. Notably, performance at low magnification (50x) was comparable to that at high magnification (1k-10kx), indicating that macro-scale features - mirror geometry and hackle line fields - already encode sufficient diagnostic signal. Grad-CAM attributions consistently localised on canonical fractographic cues (mirrors, hackles, pores, machining marks), aligning with established fractographic criteria. Together, these results position interpretable ViTs as a complementary tool for ceramic-implant quality assurance, enabling low-magnification pre-screening and reducing reliance on time-intensive high-magnification inspection.

X-ray computed tomography (XCT) is widely used for non-destructive testing of Nomex honeycomb structures in aerospace manufacturing, but industrial inspection still relies heavily on manual interpretation and supervised models trained on limited labeled data. This work introduces NL-MambaXCT, a Mamba-based framework that combines self-supervised masked image modelling with a Nested Learning (NL) formulation for automated, label-efficient defect classification from production XCT slices. The backbone is a four-stage 2D encoder with RegNet convolutional blocks in the early stages and Mamba-based sequence mixing with attention in the deeper stages. It is pretrained by masked image modelling on 19,961 unlabeled industrial XCT slices and fine-tuned on 2,000 relabeled Nomex XCT slices split by production order. NL is instantiated through two-timescale parameter dynamics: selected projections maintain slow exponential-moving-average traces alongside fast weights, while a deep-momentum optimizer introduces an additional slow parameter-update trajectory. On the held-out test set, the MIM-pretrained NL-MambaXCT model achieves 96.91% accuracy and 96.8% macro F1, outperforming CNN, attention, and single-timescale Mamba baselines by 3.11--10.31 percentage points in accuracy. The results suggest that combining masked self-supervision with NL-style fast/ slow learning dynamics is a promising strategy for robust defect classification in Nomex honeycomb XCT inspection.

Production language-model systems answer a request by partitioning it across an invisible orchestration of worker agents that recompose one integrated report. We ask what this does to a class of defect no single worker can see: a contradiction in the relation between two distant sections of a document. Holding the documents, defects, mechanism, scoring, and seed fixed, we vary only the model -- ten systems across five generations from one developer and five providers from distinct alignment paradigms. Two layers separate. First, a universal detection cliff: every model that finds these cross-section defects under a single agent loses that ability under orchestration, detection falling two-thirds or more across every paradigm tested. The cliff is mechanism-derived and not closed by scale or extended reasoning. Second, how models behave once fallen. A signal-detection decomposition shows that, among the six models discriminating above chance, only one developer's generations move along the reporting-criterion axis: as alignment is strengthened, the model misses fewer defects yet raises more false alarms on clean documents -- two faces of one criterion shift, scaling with generation within that developer (p < 0.001) and near-absent elsewhere. At the floor the missed defect is often not out of view: the model's private record reconstructs the structural fault accurately, while the integrated report signs off on its soundness, its concern spent on the artifact and an absent collaborator. This resists quantification -- an automated judge is unstable (precision 17-50%) and keywords cannot separate it from ordinary agreement -- a resistance we report as a finding. We release all runs, probes, defect keys, scorer prompts, and scripts. An integrated report's confidence is uninformative about partition-spanning defects, the most aligned systems are not the safest, and the cliff is structural.

High-resolution printed circuit board (PCB) inspection suffers from resolution collapse when full-board images are resized to standard detector inputs: micro-scale defects shrink to a few pixels and are missed. Tile-based inference preserves local detail but introduces boundary artefacts at tile edges, causing split detections and false negatives. We present a systematic comparison of five inference strategies evaluated on two high-resolution PCB defect datasets, PCB-Defect (230 images, 1704 annotations) and HRIPCB (693 images, 2 953 annotations), spanning six defect classes. We show that training-inference scale consistency is critical: a detector trained on full images collapses to mAP@50 = 0.01 under tile inference, while the same architecture trained on 640*640 tile crops achieves 0.72 and 0.94 on the two datasets respectively. We further exploited Topology-Aware Tile Merging (TA-TM), a training-free post-processing method that builds a tile-adjacency graph and adjusts boundary-sensitive detection scores using neighbour-tile agreement before global NMS. Across both datasets, adding 128 px tile overlap raises boundary-zone recall from ~26-63% to ~70-100%, TA-TM achieves the best mAP@50 on both benchmarks, and tile inference recovers 46-100% of small defects missed entirely by full-image methods. Results are consistent across datasets, confirming the generalizability of the proposed strategy. TA-TM requires no retraining and is architecture-agnostic, making it directly applicable to existing PCB inspection pipelines.

Food defect detection is critical for automated quality control, yet existing studies lack unified benchmarks and suffer from data scarcity. We introduce FDD-48, a comprehensive dataset with fine-grained annotations across 13 food types and 48 defect categories under diverse real-world conditions. To improve detection with limited labeled data, we propose FDDet, a semi-supervised framework featuring two key components: (1) BBoxMixUp, a data augmentation technique that mixes same-category defect regions to reduce spurious feature associations, and (2) CGPC (Consistency-Guided Pseudo-Label Calibration), which filters pseudo-labels based on intra-sample consistency. Experiments show FDDet significantly outperforms mainstream detectors on FDD-48, demonstrating its effectiveness for food defect detection under data-limited scenarios.

Non-destructive testing of aerospace SiC/SiC composites via X-ray computed tomography (XCT) relies on expert visual assessment, with current workflows offering limited traceability for accept/reject decisions. Deep convolutional networks can automate defect detection, yet their black-box nature conflicts with the transparency that industrial inspection practice demands. To close this gap, we introduce p-ResNet-50, a convolutional framework extended with a prototype layer that couples high detection accuracy with case-based explanations. Six learned prototypes are explicitly aligned with expert-defined semantic categories-healthy matrix, matrix--air interfaces, pores, line-like defects, and mixed morphologies-so that every classification is traceable to a physically meaningful reference. Two novel regularisation terms, anchor-based and medoid-based, tether prototypes to expert-selected patches and prevent prototype collapse, addressing a known limitation of prototype networks. Latent-space analysis via UMAP delineates semantically coherent sub-domains and maps zones of uncertainty where misclassifications concentrate, giving inspectors an explicit picture of where the model is-and is not-reliable. The framework is validated on an XCT patch dataset of approximately 12,000 patches extracted from four defect-rich SiC/SiC laboratory specimens. Taking a black-box ResNet-50 as a baseline (ROC-AUC = 0.991), the prototype extension achieves comparable performance (accuracy 0.957 vs. 0.959; ROC-AUC 0.994 vs. 0.993) while trading a slight reduction in sensitivity for higher precision and specificity. Each decision is backed by representative evidence patches, and the model explicitly flags its uncertainty regions. Beyond defect mapping, the framework establishes a reusable methodology for embedding domain-expert knowledge into prototype networks, applicable to other XCT inspection scenarios requiring traceable, auditable decisions.

Deep learning-based methods have become the de facto standard for industrial defect detection. However, their data-hungry nature and inherent "black-box" characteristics often lead to performance bottlenecks and limited trustworthiness in real-world applications. To address these challenges, this paper proposes a novel knowledge-guided loss function that seamlessly integrates model interpretability into the training process without incurring any additional inference cost. Our method operates in two phases: first, a primary classification network is trained, and its explanations, in the form of saliency maps, are generated as prior knowledge. Second, a multi-task learning framework is established, where the main task performs classification, and an auxiliary task imposes consistency between the saliency maps of the final model and the primary model. This consistency is enforced by a dedicated knowledge-guided loss term, effectively acting as a powerful regularizer to steer the model towards robust feature representations. Extensive experiments on multiple public defect datasets demonstrate that our approach consistently enhances the performance of baseline models in terms of accuracy and AP. Moreover, visual analysis reveals that the proposed method yields more concentrated and human-intelligible saliency maps. This work presents a simple yet effective paradigm for bridging the gap between model performance and interpretability, paving the way for more reliable and high-performing vision systems in industrial quality inspection.

Extracting actionable knowledge from industrial visual data is fundamentally bottlenecked by extreme class imbalance and the prohibitive computational complexity of modern foundation models. In semi-conductor manufacturing, identifying multi-label wafer defects is a complex spatial data mining task where overlapping patterns obscure critical root-cause signals. While Vision Transformers (ViTs) excel at global dependency extraction, their quadratic scaling renders them inefficient for high-throughput, real-time anomaly detection. To overcome these computational barriers, this paper introduces Hybrid Quantum-MambaVision, a highly efficient architecture tailored for spatial knowledge discovery. We integrate a linear-complexity State-Space Model (SSM) backbone with a Parameterized Quantum Context Adapter (QCA) and Low-Rank Adaptation (LoRA). The Mamba backbone efficiently captures long-range spatial dependencies, while the quantum adapter maps compressed latent features into a high-dimensional Hilbert space to disentangle complex, overlapping signatures. On the highly imbalanced MixedWM38 dataset, Hybrid Quantum-MambaVision achieves exceptional multi-label classification performance, significantly reducing the error rate on complex multi-defect topologies compared to classical baselines. The quantum regularizer acts as a profound uncertainty calibrator, substantially reducing Maximum Calibration Error (MCE) and minimizing expected false-positive costs. This work establishes a scalable Quantum-Classical hybrid paradigm for efficient representation learning in industrial data mining.

Understanding why deep neural networks (DNNs) fail to generalize to unseen samples remains a long-standing challenge. Existing studies mainly examine changes in externally observable factors such as data, representations, or outputs, yet offer limited insight into how a model's internal decision mechanism evolves from training to test. To address this gap, we introduce Decision Pattern Shift (DPS), a new perspective that defines generalization through the stability of internal decision patterns and quantifies failure as their deviation from those learned during training. Specifically, we represent each sample's decision pattern as a GradCAM-based channel-contribution vector, which captures how feature channels collectively support a prediction, and we propose the DPS metric to measure its discrepancy from the class-average pattern. Empirical analyses across multiple datasets and architectures show that, (i) decision patterns form a highly structured, class-consistent space with strong intra-class cohesion and low inter-class confusion, enabling direct analysis of a model's decision logic; (ii) the DPS magnitude correlates linearly with the generalization gap (nearly all Pearson r > 0.8), revealing generalization as a systematic drift in the model's internal decision mechanism; (iii) the DPS spectrum organizes diverse generalization degradation scenarios (covering ideal generalization, in-distribution degradation, domain shift, out-of-distribution, and shortcut learning) into a continuous trajectory, providing a unified explanation of their failure modes. These findings open up new possibilities for early generalization-risk detection, failure-mode diagnosis, and channel-level defect localization.

AI-assisted bridge defect inspection often produces bounding boxes with crude geometry or raster masks that are costly to store, transmit, and reuse. This study investigates how detected defects can be represented as compact, recoverable contour-level vector records in image space. We propose Frequency-Supervised Fourier Series Detection (FS-FSD), which directly regresses Fourier contour descriptors and evaluates boxes, masks, and contours under a unified polygon-space protocol. On 3,767 UAV-collected bridge images with 42,346 defect instances, FS-FSD achieves higher polygon-space accuracy and better matched-TP geometric quality than representative detection, segmentation, and contour baselines. These results show that, compared with bounding boxes and raster masks, Fourier contour records preserve defect-boundary geometry in a more compact, recoverable, and shareable form for engineering review and downstream information workflows. Future work will study the modeling of multi-region, fragmented, and adjacent bridge-defect boundaries and extend the framework toward long-term bridge-defect tracking and lifecycle-oriented management.

In the Industrial Internet of Things (IIoT), enabling intelligent, real-time Printed Circuit Board (PCB) defect inspection is critical for ensuring product reliability. However, existing IIoT-based visual inspection systems face two compounding challenges: scarce and imbalanced defect samples that limit model training, and insufficient feature representation under complex circuit backgrounds. Existing generation methods rely on single-modality conditions with coarse structural control, while detection methods improve architectures without addressing the data bottleneck. To resolve both challenges jointly, we propose a generation-assisted PCB defect inspection framework that integrates controlled defect synthesis with task-specific defect detection within an IIoT-enabled pipeline. On the generation side, a Multi-modal Condition Generator extracts complementary edge, depth, and text conditions in parallel. A ScaleEncoder then embeds these conditions into the diffusion U-Net at four resolutions, and a Condition Modulation applies FiLM-style spatially-adaptive modulation at each scale, enabling structurally aligned and defect-aware sample synthesis to augment the scarce IIoT dataset. On the detection side, an Inverted Residual Shift Attention couples self-attention with shift-wise convolution to jointly capture global context and local texture, and a Cross-level Complementary Fusion Block generates pixel-level gates for selective cross-level feature fusion. The synthesized samples directly enrich the detection training set, so that improvements in generation compound with improvements in detection. Extensive experiments on DsPCBSD+ demonstrate that UniPCB achieves mAP@0.5 of 98.0% and mAP@0.5:0.95 of 61.8% on defect detection, surpassing all compared methods, while the generation branch attains an FID of 129.61 and SSIM of 0.619, outperforming existing conditional generation approaches.

Tunnel inspection requires outputs that can support defect localization, measurement, severity grading, and engineering documentation. Existing training-free foundation-model pipelines usually stop at coarse open-vocabulary proposals, which are difficult to use directly in interference-heavy tunnel scenes. We propose a training-free framework TunnelMIND. Specifically, language-guided defect proposals are not treated as final outputs; instead, their spatial support is recalibrated at inference time through dense visual consistency, so that coarse semantic anchors can be transformed into more reliable prompts under tunnel-specific hard negatives. The resulting masks are further reconstructed into structured defect entities with category, location, geometry, severity, and context attributes, which are then mapped to retrieval-grounded explanation and engineering-readable report generation under expert knowledge constraints. On visible, GPR, and road defect tasks, TunnelMIND achieves F1 scores of 0.68, 0.78, and 0.72, respectively. Overall, TunnelMIND shows that training-free tunnel inspection can move beyond coarse localization toward structured defect evidence for engineering assessment.

The bottleneck in learning-based industrial defect detection is often limited not by model capacity, but by the scarcity of labeled defect data: defects are rare, annotations are expensive, and collecting balanced training sets is slow. We present an end-to-end pipeline for synthetic defect generation and annotation, combining Vision-Language-Model-based prompts, LoRA-adapted diffusion, mask-guided inpainting, and sample filtering with automatic label derivation, and demonstrates the potential of real data with realistic synthetic samples to overcome data scarcity. The evaluation is conducted on, a challenging dataset of pitting defects on ball screw drives, and then on a subset of the Mobile phone screen surface defect segmentation dataset (MSD) dataset to test cross-domain transfer. Beyond downstream detector performance, we analyze key stages of the pipeline, including prompt construction, LoRA selection, and sample filtering with DreamSim and CLIPScore, to understand which synthetic samples are both realistic and useful. Experiments with YOLOv26, YOLOX, and LW-DETR show that synthetic-only training does not replace real data. When combined with real data, synthetic defects can preserve performance and yield modest gains in selected BSData training regimes. The MSD transfer study shows that the overall pipeline structure carries over to a second industrial inspection domain, while also highlighting the importance of domain-specific adaptation and annotation-quality control. Overall, the paper provides an end-to-end assessment of diffusion-based industrial defect synthesis and shows that its strongest value lies in strengthening scarce real datasets rather than substituting for them.

The increasing global deployment of solar photovoltaic (PV) systems needs robust, scalable, and automated inspection technologies capable of detecting a wide range of panel flaws under a variety of operating situations. The lack of large-scale, multi-modal, publicly available annotated datasets is a major obstacle preventing advancement in this field. We introduce SolarFCD, an extensive dataset of solar panel defects created by methodically combining and reconciling three publicly accessible datasets covering two imaging modalities: RGB/Drone images and Thermal Infrared. The dataset consist of 4,435 images arranged under four unified defect classes such as: healthy images, Surface Obstruction, structural fault, and electrical fault. The dataset was divided into training, validation, and test splits at an 80:10:10 ratio through methodical label mapping, near-duplicate removal, and targeted augmentation of minority classes. Sixteen classification architectures from five design families were trained and assessed on the dataset to provide repeatable benchmark baselines. With an accuracy of 86.68%, precision of 88.65%, recall of 88.62%, and F1-score of 88.17%, ResNet101V2 performed the best overall. Per-class results showed balanced detection across all four defect categories within a narrow performance band of less than 1.2 percentage points. To promote open and repeatable research in automated PV inspection and solar energy operations and maintenance, the dataset, annotation files, and baseline code are made openly available.

This paper presents an IoT-enhanced deep learning framework for automated crack detection in Additive Manufacturing (AM) surfaces using convolutional neural networks (CNNs). By integrating IoT-enabled real-time monitoring, high-resolution imaging, and edge computing, the system enables continuous in-situ defect detection and classification. Real-time data acquisition supports immediate CNN-based analysis, improving both accuracy and efficiency in AM quality control. The framework supports supervised and semi-supervised learning, enabling robust performance on large, sparsely annotated datasets. Using LabelImg for annotation and OpenCV for preprocessing, the system achieves 99.54% accuracy on 14,982 images, with 96% precision, 98% recall, and a 97% F1-score. Dataset balancing and augmentation significantly improve generalization, increasing accuracy from 32% to 99%. Beyond detection, the framework establishes a linkage between AM process parameters, defect formation, and surface topology, supporting predictive analytics and defect mitigation. Aligned with Industry 4.0, it incorporates Digital Twin (DT) technology for real-time process simulation, predictive maintenance, and adaptive control. Key contributions include an IoT-based monitoring system using edge devices (Raspberry Pi 4B), an optimized CNN with model quantization and batch processing reducing inference latency by 47%, and an MQTT-based low-latency data streaming system with 5G connectivity, lowering transmission overhead by 35%. DT integration further enables predictive defect analysis and dynamic adjustment of AM parameters. This work advances intelligent AM quality control by providing a scalable, high-accuracy, and low-latency framework. Future directions include multimodal data fusion, hybrid architectures, and enhanced Digital Twin simulations for AI-driven defect prevention.

Industrial visual inspection systems often suffer from a severe scarcity of labeled defect data, particularly during the early stages of New Product Introduction (NPI). This limitation hinders the deployment of robust supervised detectors precisely when automated quality control is most needed. We present an end-to-end generative framework for high-fidelity, few-shot defect synthesis that enables both in-domain augmentation and cross-domain transfer. Our approach disentangles defect morphology from background appearance by combining masked textual inversion for defect representation learning, noise-blended conditioned generation for surface-aware synthesis, and gradient-aware post-processing for seamless visual integration. We evaluate the framework in two practically relevant settings: few-shot data augmentation, where synthetic samples enrich a small set of real defects, and zero-shot adaptation, where defects learned from a source domain are transferred to a novel target surface without any real target-domain defect examples. Using RF-DETR as the downstream detector, we show that the proposed pipeline substantially narrows the domain gap on a private industrial dataset. In the few-shot setting, synthetic augmentation improves mAP from 78.8% to 83.3%. In the zero-shot setting, synthetic domain adaptation improves mAP from 65.0% to 85.1%. These results demonstrate that high-fidelity defect synthesis can meaningfully accelerate NPI by enabling effective inspection models before sufficient real defect data has been collected.

Multi-class defect detection constitutes a critical yet challenging task in industrial quality inspection, where existing approaches typically suffer from two fundamental limitations: (i) the necessity of training separate models for each defect category, resulting in substantial computational and memory overhead, and (ii) degraded robustness caused by inter-class feature perturbation when heterogeneous defect categories are jointly modeled. In this paper, we present FPFNet, a Feature Perturbation Pool-based Fusion Network that synergistically integrates a stochastic feature perturbation pool with a multi-layer feature fusion strategy to address these challenges within a unified detection framework. The feature perturbation pool enriches the training distribution by randomly injecting diverse noise patterns -- including Gaussian noise, F-Noise, and F-Drop -- into the extracted feature representations, thereby strengthening the model's robustness against domain shifts and unseen defect morphologies. Concurrently, the multi-layer feature fusion module aggregates hierarchical feature representations from both the encoder and decoder through residual connections and normalization, enabling the network to capture complex cross-scale relationships while preserving fine-grained spatial details essential for precise defect localization. Built upon the UniAD architecture~\cite{you2022unified}, our method achieves state-of-the-art performance on two widely adopted benchmarks: 97.17% image-level AUROC and 96.93% pixel-level AUROC on MVTec-AD, and 91.08% image-level AUROC and 99.08% pixel-level AUROC on VisA, surpassing existing methods by notable margins while introducing no additional learnable parameters or computational complexity.

Industrial surface defect detection often suffers from limited defect samples, severe long-tailed distributions, and difficulties in accurately localizing subtle defects under complex backgrounds. To address these challenges, this paper proposes an unsupervised defect detection method that integrates a Denoising Diffusion Probabilistic Model (DDPM) with an asymmetric teacher-student architecture. First, at the data level, the DDPM is trained solely on normal samples. By introducing constant-variance Gaussian perturbations and Perlin noise-based masks, high-fidelity and physically consistent defect samples along with pixel-level annotations are generated, effectively alleviating the data scarcity problem. Second, at the model level, an asymmetric dual-stream network is constructed. The teacher network provides stable representations of normal features, while the student network reconstructs normal patterns and amplifies discrepancies between normal and anomalous regions. Finally, a joint optimization strategy combining cosine similarity loss and pixel-wise segmentation supervision is adopted to achieve precise localization of subtle defects. Experimental results on the MVTecAD dataset show that the proposed method achieves 98.4% image-level AUROC and 98.3% pixel-level AUROC, significantly outperforming existing unsupervised and mainstream deep learning methods. The proposed approach does not require large amounts of real defect samples and enables accurate and robust industrial defect detection and localization. \keywords{Industrial defect detection \and diffusion models \and data generation \and teacher-student architecture \and pixel-level localization}

Automated segmentation of structural defects from visual inspection imagery remains challenging due to the diversity of damage types, extreme class imbalance, and the need for precise boundary delineation. This paper presents DeltaSeg, a U-shaped encoder-decoder architecture with a tiered attention strategy that integrates Squeeze-and-Excitation (SE) channel attention in the encoder, Coordinate Attention at the bottleneck and decoder, and a novel Deep Delta Attention (DDA) mechanism in the skip connections. The encoder uses depthwise separable convolutions with dilated stages to maintain spatial resolution while expanding the receptive field. Atrous Spatial Pyramid Pooling (ASPP) at the bottleneck captures multi-scale context. The DDA module refines skip connections through a dual-path scheme combining a learned delta operator for nuisance feature suppression with spatial attention gates conditioned on decoder signals. Deep supervision through multi-scale auxiliary heads further strengthens gradient flow and encourages semantically meaningful features at intermediate decoder stages. We evaluate DeltaSeg on two datasets: the S2DS dataset (7 classes) and the Culvert-Sewer Defect Dataset (CSDD, 9 classes). Across both benchmarks, DeltaSeg consistently outperforms 12 competing architectures including U-Net, SA-UNet, UNet3+, SegFormer, Swin-UNet, EGE-UNet, FPN, and Mobile-UNETR, demonstrating strong generalization across damage types, imaging conditions, and structural geometries.

To ensure energy efficiency and reliable operations, it is essential to monitor solar panels in generation plants to detect defects. It is quite labor-intensive, time consuming and costly to manually monitor large-scale solar plants and those installed in remote areas. Manual inspection may also be susceptible to human errors. Consequently, it is necessary to create an automated, intelligent defect-detection system, that ensures continuous monitoring, early fault detection, and maximum power generation. We proposed a novel hybrid method for defect detection in SOLAR plates by combining both handcrafted and deep learning features. Local Binary Pattern (LBP), Histogram of Gradients (HoG) and Gabor Filters were used for the extraction of handcrafted features. Deep features extracted by leveraging the use of DenseNet-169. Both handcrafted and deep features were concatenated and then fed to three distinct types of classifiers, including Support Vector Machines (SVM), Extreme Gradient Boost (XGBoost) and Light Gradient-Boosting Machine (LGBM). Experimental results evaluated on the augmented dataset show the superior performance, especially DenseNet-169 + Gabor (SVM), had the highest scores with 99.17% accuracy which was higher than all the other systems. In general, the proposed hybrid framework offers better defect-detection accuracy, resistance, and flexibility that has a solid basis on the real-life use of the automated PV panels monitoring system.

This paper addresses the limitations of current vision-based rail defect detection methods, including high computational complexity, excessive parameter counts, and suboptimal accuracy. We propose a Lightweight Pyramid Cross-Attention Network (LPCANet) that leverages RGB-D data for efficient and accurate defect identification. The architecture integrates MobileNetv2 as a backbone for RGB feature extraction with a lightweight pyramid module (LPM) for depth processing, coupled with a cross-attention mechanism (CAM) for multimodal fusion and a spatial feature extractor (SFE) for enhanced structural analysis. Comprehensive evaluations on three unsupervised RGB-D rail datasets (NEU-RSDDS-AUG, RSDD-TYPE1, RSDD-TYPE2) demonstrate that LPCANet achieves state-of-the-art performance with only 9.90 million parameters, 2.50 G FLOPs, and 162.60 fps inference speed. Compared to 18 existing methods, LPCANet shows significant improvements, including +1.48% in $S_α$, +0.86% in IOU, and +1.77% in MAE over the best-performing baseline. Ablation studies confirm the critical roles of CAM and SFE, while experiments on non-rail datasets (DAGM2007, MT, Kolektor-SDD2) validate its generalization capability. The proposed framework effectively bridges traditional and deep learning approaches, offering substantial practical value for industrial defect inspection. Future work will focus on further model compression for real-time deployment.