Finite Element Method

pyforce is a Python package implementing Data-Driven Reduced Order Modelling techniques for applications to multi-physics problems, mainly set in the Nuclear Engineering world. The package is part of the ROSE (Reduced Order modelling with data-driven techniques for multi-phySics problEms): mathematical algorithms aimed at reducing the complexity of multi-physics models (for nuclear reactors applications), at searching for optimal sensor positions and at integrating real measures to improve the knowledge on the physical systems. With respect to the previous original implementation based on dolfinx package (v0.6.0), version 1.0.0 of pyforce has been completely re-written using pyvista as backend for mesh importing, computing integrals, and visualisation of results; in addition, functions are stored as numpy arrays, improving the ease of use of the package. This choice allows to use pyforce with any software solver able to export results in VTK format.

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.

The demand for clean energy is ever increasing, with new nuclear technologies presenting a complementary solution to renewable energies. However, designing and operating these systems is exceptionally difficult, given the complexity of the physical phenomena that interact to form the system dynamics. While high-fidelity simulations help to understand the non-linear, multi-physics interactions within a reactor, they are computationally expensive and rarely suitable for real-time applications. Furthermore, model-based approaches are inherently sensitive to simplifying assumptions required to derive their governing equations and parameters, leading to inevitable discrepancies with real-world measurements. In contrast, Machine Learning (ML) methods have the potential to generate reliable surrogate models which may be able to quickly predict the system's behaviour. However, the number of data-driven methods that can potentially be used for this task is large and diverse. In a safety-critical setting such as nuclear engineering, a fair comparison of different ML methods, and a clear understanding of their advantages and limitations, is of paramount importance. To address this, we introduce a Common Task Framework (CTF) for ML in nuclear engineering, building upon previous efforts in dynamical systems and seismology. This CTF considers a curated set of datasets from different nuclear and nuclear-adjacent systems. The CTF evaluates the performance of a method on 12 established metrics, alongside a new paradigm focused on system monitoring from sparse measurements only. We illustrate the framework by benchmarking standard ML baselines against these datasets, revealing current method limitations. Our vision is to replace ad hoc comparisons with standardized evaluations on hidden test sets, raising the bar for rigour and reproducibility in scientific ML for the nuclear industry.

Explicit dynamic finite element (FE) simulations are widely used for large deformation engineering analysis, but repeated simulations remain costly during design space exploration and optimisation. In explicit FE analysis, nodal kinematics and element level deformation measures evolve through coupled node element updates. This motivates graph learned simulators that approximate one step FE state transitions and roll them out autoregressively. However, many mesh based graph surrogates are node centred, which makes element level variables and native nodal elemental exchange less direct to represent. This work proposes CAttBiGNN, a cross attention based bipartite graph neural network for coupled nodal elemental learning. The graph represents FE mesh nodes and elements as distinct entities linked by directed node element edges, enabling nodal displacement increments and element level deformation states to be predicted on their native discretisation domains. An edge aware cross attention processor uses geometric edge embeddings to modulate directional node element message passing. For larger graphs, CAttBiUGNN combines the bipartite processor with graph downsampling and upsampling to improve long-range information propagation. The method is evaluated on dome shaped cold forming and corner shaped hot forming benchmarks. Comparisons with node centred baselines and bipartite and attention ablations show improved accuracy and balance in nodal displacement and elemental thinning prediction during autoregressive rollout. The results indicate that the proposed finite element inspired learned simulator can support manufacturability oriented field prediction and efficient design space exploration in large deformation sheet material forming.

Differentiable simulation of soft bodies is a foundation for system identification, trajectory optimization, and Real2Sim transfer. Yet, existing methods such as the differentiable Projective Dynamics (DiffPD) struggle when faced with heterogeneous materials with extreme stiffness contrasts, hyperelasticity under large deformations, and contact-rich interactions, which are common scenarios in the real world. We present DiffPhD, a unified GPU-accelerated differentiable Projective Dynamics framework for heterogeneous materials that tackles these intertwined challenges simultaneously. Our key insight is a careful integration of: (i) stiffness-aware projective weights to embed heterogeneity into the global system; (ii) trust-region eigenvalue filtering lifted to the backward pass for stable hyperelastic gradients and a type-II Anderson Acceleration scheme with dual-gate convergence to stabilize forward iteration under large stiffness contrasts; and (iii) a unified GPU pipeline that reuses a single sparse factor across forward, backward, and contact computations, with stiffness-amplified Rayleigh damping folded into the same factor for heterogeneity-aware dissipation at zero recurring cost. DiffPhD achieves strict gradient accuracy while delivering up to an order-of-magnitude speedup over prior differentiable solvers on heterogeneous, hyperelastic, contact-rich benchmarks. Crucially, this speedup does not come at the cost of stability: DiffPhD remains convergent on stiffness contrasts up to 100x where prior PD solvers degrade. This unlocks end-to-end gradient-based optimization on regimes previously bottlenecked by either solver fragility or per-iteration cost -- shell--joint composite creatures, soft characters wielding stiff weapons, and soft-gripper robotic manipulation -- all handled within a single forward--backward pass.

Nonlinear finite element crash simulations are accurate but computationally expensive, limiting their use in iterative design optimisation. Machine-learning surrogate models based on graph neural networks (GNNs) offer a faster alternative. Message-passing GNNs are widely used for mesh simulation, and their shared node and edge update functions are relatively generalisable across varying graph structures. By contrast, non-shareable edge-specific aggregation layers can capture nonlinear relationships more accurately but usually require fixed graph connectivity, which limits generalisability. This paper presents Mask-Morph Graph U-Net (MMGUNet), a practical approach to addressing the limitation of hierarchical Graph U-Net architectures that use edge-specific downsampling and upsampling layers. Fixed coarse graph connectivity is required for edge-specific layers. To retain this while improving spatial correspondence, the proposed method morphs the coarsened graph hierarchy to each input mesh using feature-aligned barycentric parameterisation before constructing cross-graph edges. It further applies node masking during supervised pretraining, followed by parameter-efficient fine-tuning in which high-parameter edge-specific layers are frozen. The proposed approach is evaluated in in-distribution, out-of-distribution, and cross-component transfer settings using mean Euclidean distance and maximum intrusion percentage error. Results show that coarse-graph morphing improves test accuracy relative to a fixed-coarse-graph baseline, while masked supervised pretraining reduces the train-test discrepancy and improves data efficiency during transfer. The proposed model also achieves lower prediction error compared with external baselines. These results demonstrate a practical route toward reusable, data-efficient mesh-based surrogate modelling for crashworthiness design exploration.

Traditional sheet metal forming relies on time-consuming and expensive Finite Element Analysis (FEA) for design validation, a process that significantly prolongs design cycles. While surrogate models offer faster iteration, current approaches have limitations: scalar-based methods cannot capture comprehensive field-based FEA results, while existing image-based models often ignore the critical role of material properties by focusing solely on geometry. To address this gap, we develop a physics-guided deep learning framework, namely StampFormer, which simultaneously uses component geometry and material stress-strain responses to predict FEA outcomes. The StampFormer framework uses three core components to process data. A Material-Augmented Geometric Network (MAGN) first fuses geometric and material data. This information is then integrated at various levels by a Hierarchical Material Embedding Injection Unit (HMEIU) before being processed by the primary network backbone, an adapted Swin-UNet. We evaluated our model on the stamping of a crossmember panel with two simulation datasets for steel and aluminium panels, and results demonstrate that StampFormer provides high-fidelity predictions of critical physical fields - including thinning, major strain, minor strain, plastic strain, and displacement - in under a second. Compared with ground truth FEA, our model achieved an average relative error of less than 8.5% on the four 2D fields and a mean squared error of less than 1.2 mm2 for the 3D displacement field. In summary, we introduce a practical and efficient framework that integrates multimodal information, namely geometry and material properties, to provide fast and accurate predictions, enabling designers to perform real-time manufacturability assessments.

Full-vehicle crash simulations are computationally expensive, limiting their use in iterative design exploration. This work investigates learned hybrid surrogate models (MeshTransolver, MeshGeoTransolver, and MeshGeoFLARE) for predicting time-resolved structural deformation fields in an industrial lateral pole-impact benchmark. We evaluate whether neural surrogates can reproduce full-field crash kinematics with sufficient accuracy, spatial regularity, and structural plausibility for engineering interpretation. The proposed architectures combine local mesh message passing, geometry-aware global attention, and sparse contact-aware correction for autoregressive crash rollout. We compare mesh-based graph neural networks, attention-based geometric models, and hybrid architectures under a common training and hyperparameter configuration. The hybrid models capture both short-range structural interactions and long-range deformation patterns, while a sparse contact-aware variant assesses the effect of dynamic proximity interactions during rollout. On a 25-sample full-vehicle test set, the best hybrid model achieves a temporal mean root-mean-square error of 3.20 mm. While geometry-aware attention baselines are quantitatively competitive, qualitative side-view inspection shows they can introduce local spatial noise and deformation irregularities that complicate structural interpretation. In contrast, hybrid mesh-attention models provide the best balance between scalar accuracy, survival-space consistency, and physically interpretable displacement fields. These results suggest that crash surrogate assessment should combine global error metrics with downstream safety-relevant quantities and qualitative field inspection. The proposed methodology enables fast full-field predictions while preserving essential structural information for industrial crash-engineering analysis.

PDE-to-solver code generation aims to automatically synthesize executable numerical solvers from partial differential equation (PDE) specifications. This task requires not only understanding the mathematical structure of PDEs, but also selecting appropriate discretization schemes and solver configurations, and correctly implementing the resulting formulations in finite-element method (FEM) libraries. Existing code generation benchmarks mainly evaluate syntactic correctness, or success on predefined test cases. To our knowledge, there is currently no publicly available benchmark specifically for PDE-to-solver code generation, and general-purpose code benchmarks do not fully capture the unique challenges of numerical PDE solution, such as ensuring solver accuracy, efficiency, and compatibility with professional FEM libraries. We introduce PDEAgent-Bench, to the best of our knowledge, the first multi-metric, multi-library benchmark for PDE-to-solver code generation. PDEAgent-Bench contains 645 instances across 6 mathematical categories and 11 PDE families, with common FEM libraries for DOLFINx, Firedrake, and deal.II. Each instance provides an agent-facing problem specification, a reference solution on a prescribed evaluation grid, and case-specific accuracy and runtime targets. PDEAgent-Bench adopts a staged evaluation framework in which generated solvers must sequentially pass executability, numerical accuracy, and computational efficiency checks. Experiments with representative LLMs and code agents show that models can often produce runnable code, but their pass rate drops substantially once accuracy and efficiency requirements are enforced. These results indicate that current agents remain limited in producing numerically reliable and efficient PDE solvers, and that PDEAgent-Bench provides a reproducible testbed grounded in the practical requirements of numerical PDE solving.

Execution-based evaluation of LLM-generated code implicitly treats successful execution as a proxy for correctness. In scientific simulation, this proxy is insufficient: a generated input file can run, mesh, and converge while encoding governing equations that differ from the user's intent. We call this mismatch between intended physics and generated code the comprehension-generation gap. We instantiate this in MOOSE, where Kernel and BC objects map compositionally to weak-form residual terms, enabling deterministic reconstruction of the encoded PDE and comparison against an intended contract. We formalize this comparison as the Intent Fidelity Score (IFS), a structural metric covering governing terms, BCs, ICs, coefficients, and time scheme. Building on IFS, we develop a PDE-grounded refinement loop that uses deterministic violation reports to correct generated code iteratively. We evaluate on MooseBench, a 220-case multiphysics benchmark with PDE-level ground truth released with this work. On this benchmark, our method consistently improves mean IFS over direct generation, with gains concentrated on hard cases. On the subset where direct generation falls below IFS 0.7, refinement adds +0.22 to +0.41 absolute IFS. In the deployment audit, execution-only repair improves execution success while leaving 39-40% of all 220 cases runnable but still solving the wrong physics across the three main deployment-audit models, exposing executability and intent fidelity as separable failure modes. Static proof-of-concept experiments on four PDE-oriented DSLs (UFL/FEniCS, FreeFEM, FiPy, and Devito) suggest that the reconstruction-and-comparison pattern extends beyond MOOSE. These findings reinforce that executable simulation code should be verified against the mathematical structure it is intended to encode, not accepted on execution alone.

Physics-informed operator learning is an attractive candidate for surrogate modeling of microstructures, especially in multiscale finite-element simulations. Its practical use, however, is often limited by the high cost of loss evaluation. We address this bottleneck by combining the Equilibrium Neural Operator (EquiNO) with the QR-based discrete empirical interpolation method (Q-DEIM). EquiNO learns only the modal coefficients of reduced displacement-fluctuation and first Piola-Kirchhoff stress representations built from periodic and divergence-free bases, thereby enforcing periodicity and mechanical equilibrium by construction. Q-DEIM then identifies a small set of spatial points through a column-pivoted QR factorization of the stress basis and restricts constitutive evaluations during training to these points alone. This makes full-batch second-order optimization practical for three-dimensional representative volume elements (RVEs). Homogenized first Piola-Kirchhoff stresses are recovered directly from the offline-averaged reduced stress modes, without the need to reconstruct the full stress field at inference time. We validate the framework on two three-dimensional finite-strain hyperelastic RVEs. Q-DEIM reduces the per-step training cost by roughly three orders of magnitude relative to full-field loss evaluation, while reduced homogenization achieves speed-up factors of order $10^3$ to $10^4$ over direct full-field computations. Despite relying on only a small number of offline snapshot loading paths for basis construction, the method accurately interpolates and extrapolates both microscopic stress fields and homogenized stresses, with prediction quality improving systematically as more snapshots are added.

Accurate prediction of structural displacements under external loading is fundamental to structural health monitoring and seismic safety assessment. Although the finite element method (FEM) remains the prevailing approach because of its high accuracy, its considerable computational cost restricts its suitability for real-time monitoring applications. To address this limitation, this study proposes a data-driven framework based on Graph Neural Networks (GNNs), in which structural systems are represented as graphs with joints modeled as nodes and structural members as edges. By incorporating both geometric and mechanical properties into the graph representation, the proposed model learns the relationship between applied loads and structural responses directly from simulated data. A synthetic dataset was generated from a two-story frame structure using ANSYS, and both a conventional Neural Network (NN) and a GNN were trained for comparison. The results show that the proposed GNN framework predicts displacements and rotations with high accuracy and outperforms the NN model, demonstrating its potential as a fast and efficient alternative to traditional FEM-based analysis.

Crash simulation is a cornerstone of modern vehicle development because it reduces the need for costly physical prototypes, accelerates safety-driven design iteration, and increasingly supports virtual testing workflows. At the same time, modeling structural crash mechanics remains exceptionally challenging: the response is governed by nonlinear contact, large deformation, material plasticity, failure, and complex multi-body interactions evolving over space and time on high-resolution finite-element meshes. In this work, we introduce CarCrashNet, a public high-fidelity open-source benchmark for data-driven structural crash simulation. CarCrashNet combines component-scale and full-vehicle simulations in a multi-modal format, including more than 14,000 bumper-beam pole-impact simulations with varying geometry, materials, and boundary conditions, together with 825 full-vehicle crash simulations built from three industry-standard vehicle models of increasing structural complexity: Dodge Neon, Toyota Yaris, and Chevrolet Silverado. To establish the reliability of the benchmark, we validate our open-source finite-element workflow based on OpenRadioss against both experimental crash data and the commercial solver Ansys LS-DYNA. We also introduce CrashSolver, a machine-learning model designed for full-vehicle crash prediction from high-resolution finite-element crash data. We further perform extensive benchmarking across the released datasets and evaluate CrashSolver against state-of-the-art geometric deep learning and transformer-based neural solvers. Our results position CarCrashNet as a foundation for reproducible research in structural simulation, crashworthiness modeling, and AI-driven virtual crash testing. The dataset is available at https://github.com/Mohamedelrefaie/CarCrashNet.

Elastic ribbons, slender structures whose length ($L$), width ($W$), and thickness ($b$) satisfy $L \gg W \gg b$, exhibit mechanical behaviors intermediate between one-dimensional rods ($L \gg W, b$) and two-dimensional plates ($L, W \gg b$). In quadratic Kirchhoff-type rod-based frameworks, such as Discrete Elastic Rods (DER), the governing equilibrium equations are independent of width, and therefore these models cannot capture width-dependent mechanical effects. Reduced centerline-based ribbon models attempt to capture width dependence via coupled bending-twisting energies. However, their relative accuracy remain unclear due to the absence of a unified simulation framework. In this work, we formulate a framework grounded in discrete differential geometry where the energy is expressed as functions of coupled bending-twisting strain measures along the centerline, rather than a linear sum of quadratic bending and twisting energies in DER. We derive analytical gradients and Hessians of the energy that enable implicit time integration. Within this unified setting, we compare five ribbon models: Kirchhoff, Sadowsky, Wunderlich, Sano, and Audoly. As a benchmark, a straight ribbon is longitudinally constrained into a pre-buckled arch and subjected to transverse displacement, inducing a supercritical pitchfork bifurcation. Predicted bifurcation thresholds are compared against shell-based finite element simulations, with the Sano model providing the closest agreement in capturing width-dependent shifts. Our high-performance JAX-based implementation achieves $\mathcal{O}(N)$ per-iteration cost and also confirms that Sano model introduces negligible per-iteration overhead relative to standard DER.

Tactile perception is key to dexterous manipulation, yet simulating high-resolution elastomer deformation remains computationally prohibitive. Finite element methods (FEM) deliver high fidelity but demand costly remeshing, while Material Point Methods (MPM) suffer from heavy particle-memory tradeoffs. We propose a {reduced-order neural simulation framework} that couples coarse-grained MPM dynamics with an implicit neural decoder to reconstruct sub-particle tactile details from compact latent states. The framework learns a continuous deformation manifold from paired high- and low-resolution simulations, enabling physically consistent, differentiable inference. Compared to the TacIPC, our method achieves over 65% faster simulation and {40% lower memory usage}, while maintaining better geometric fidelity. In tactile rendering and 3D surface reconstruction, our methods further improve accuracy by 25% and produce realistic depth images and surface mesh within a faster inference speed. These results demonstrate that the proposed reduced-order neural model enables high-detail, physically grounded tactile simulation with substantial efficiency gains for robotic interaction and optimization.

Large Language Models (LLMs) are democratizing access to personalized tutoring; however, their effectiveness is hindered by challenges in processing multimodal content, which limits AI's potential to provide equitable, high-quality STEM support. This study evaluates LLM performance on multimodal physics problems, identifies specific failure modes through an empirical error taxonomy, and tests practical interventions designed to overcome multimodal processing limitations. We assessed three publicly available LLMs (Claude, Gemini, and ChatGPT) on multimodal physics problems from the OpenStax database and compared the results with text-only performance. An empirically derived error taxonomy was developed through pilot testing, followed by evaluation of a structured multimodal dialogue intervention. All three models achieved near-ceiling accuracy (96%) on text-only physics problems. Performance declined substantially on multimodal problems, consistent with what we term the Multimodal Interference Effect. Error analysis identified four failure modes: visual processing errors, context misinterpretation, mathematical computational errors, and hybrid errors, with visual processing errors being the most prevalent. The structured dialogue intervention corrected 82% of errors overall; visual processing errors were corrected at 100% across all models. Educators and students can implement these interventions immediately, requiring no model retraining, to improve AI tutoring reliability on image-rich STEM content, advancing equitable access to high-quality learning support.

Multiphysics simulation is critical for system-technology co-optimization (STCO) in chiplet-based design, but repeated finite-element solutions of PDE-governed problems are computationally expensive in parametric design exploration. This paper proposes a variational matrix-learning Fourier network (VMLFN) for efficient parametric multiphysics surrogate modeling. VMLFN constructs a log-space sine neural representation with randomly sampled spectral frequencies, frequency-dependent decay regulation, and embedded Dirichlet boundary conditions. With fixed hidden-layer parameters, the output-layer weights are determined by reformulating the governing PDEs into variational weak forms and enforcing the stationarity condition of the resulting energy functional. This converts physics-informed training into a linear matrix-solving problem, requiring only first-order derivatives and avoiding both high-order automatic differentiation and penalty-coefficient tuning. A heuristic frequency-scanning algorithm is further introduced to select a problem-adaptive maximum frequency that covers the dominant spectral range of the target problem. The proposed method is validated on heat conduction, solid mechanics, and Helmholtz wave propagation problems. Results from five benchmark cases demonstrate that VMLFN delivers accurate full-field predictions with substantial speedup over conventional physics-informed neural networks and repeated finite-element simulations.

We present CRADIPOR, a numerical dispersion prediction tool for automotive crash simulations. Finite Element (FE) crash models are widely used throughout vehicle development, but their predictions are not strictly repeatable because of parallel computation and model complexity. As a result, performance criteria evaluated during post-processing may exhibit significant numerical dispersion, which complicates engineering decision-making. Although dispersion can be estimated by repeating the same simulation, this approach is generally impractical because of its high computational cost. This work therefore investigates a prediction tool that can be applied during routine crash-simulation post-processing without repeating the computation. The proposed approach relies on a Rank Reduction Autoencoder (RRAE) combined with supervised classification in order to identify regions sensitive to numerical dispersion. The comparative analysis suggests that the RRAE-based framework is more effective than the Random Forest baseline on the studied dataset. Among the tested signal representations, wavelet-based and slope-based inputs appear to be the most promising, with slope variations providing the best classification performance. These results support the use of structured latent representations for improving numerical-dispersion detection in automotive crash post-processing.

We introduce a new framework for room acoustics modelling based on a state-space model of the boundary integral equation representing the sound field in a room. Whereas state-space models of linear time-invariant systems are traditionally constructed by means of a state vector and a 4-tuple of system matrices, the state-space representation introduced in this work consists of a state function representing the pressure distribution at the room boundary, and a 4-tuple of integral operators. We refer to this representation as a boundary integral operator state-space (BIOSS) model and provide a physical interpretation for each of the integral operators. As many mathematical operations on vectors and matrices translate to functions and operators, the BIOSS representation can be manipulated to obtain two transfer function representations, having either a feedback or a parallel feedforward structure. Consequently, various equivalent representations for room acoustics are obtained in the BIOSS framework, in the time or frequency domain, and in continuous or discrete space. We discuss two future directions for how the proposed framework can be fertile for research on room acoustics modelling. Firstly, we identify equivalences between the BIOSS framework and various existing room acoustics models (boundary element models, delay networks, geometric models), which may be used to establish relations between existing models and to develop novel room acoustics models. Secondly, we postulate on how concepts from state-space theory, such as observability, controllability, and state realization, can be used for developing new inference and control methods for room acoustics.

We present GeoTransolver, a multiscale geometry-aware physics attention transformer for Computer Aided Engineering (CAE). GeoTransolver extends the Transolver backbone with GALE (Geometry-Aware Latent Embeddings) attention, which pairs physics-aware self-attention on learned state slices with cross-attention to a shared geometry and global context computed via multi-scale ball queries (inspired by Domino) and reused in every block. Implemented and released in NVIDIA PhysicsNeMo, GeoTransolver persistently projects geometry and global parameters, into physical state spaces to anchor computations to domain structure and operating regimes. We benchmark on DrivAerML, SHIFT-SUV, and SHIFT-Wing against Domino, Transolver (PhysicsNeMo implementation), and literature-reported AB-UPT, evaluating drag/lift R2 and relative L1 errors on field variables. As an additional nonlinear structural mechanics application, we also report Transolver and GeoTransolver results on bumper-beam and full-vehicle Body-in-White (BIW) crash-dynamics benchmarks, evaluating relative L2 trajectory error and probe-level kinematic MSE. GeoTransolver delivers improved accuracy, robustness to geometry and regime shifts, and favorable data efficiency; we include DrivAerML ablations and qualitative contour and design-trend results, advancing operator learning for high-fidelity surrogates on complex, irregular, non-linear domains.

The geometric morphology of deposited filaments can significantly influence the structural performance and stability of 3D concrete-printed (3DCP) structures. However, most finite element (FEM)-based approaches for buildability assessment represent printed layers as simplified rectangles, potentially limiting predictive accuracy. This study proposes a geometry-informed modelling framework that integrates the deep-learning-based filament shape prediction tool ShapeGen3DCP with a layer-activation FEM approach to investigate the effect of realistic filament geometries on buildability. The framework generates geometry-aware numerical models directly from material and process parameters, eliminating the need for experimental filament characterization or computationally intensive fluid-flow simulations. Validation against experimental data and a parametric study of rectilinear walls demonstrate that extrusion parameters and the resulting filament geometry can significantly influence buildability predictions. Realistic filament representations are particularly important for free-flow deposition, whereas layer-pressing strategies are less sensitive to geometric simplifications. Among the investigated representations, an elliptical approximation provides an effective balance between geometric fidelity and modelling simplicity. When rectangular representations are preferred to enable regular computational meshes for faster simulations, defining their dimensions based on volume conservation improves prediction reliability compared with calibrating them using either the maximum filament width or the interlayer contact width. Overall, the proposed methodology demonstrates the importance of incorporating filament geometry into 3DCP simulations and provides practical guidance for selecting efficient and accurate geometric representations for buildability assessment.