Additive Manufacturing

We built a robot called the Robotroller that actuates an Atari CX40+ controller and a device called the Atari Devbox that renders the game frame and the reward signal from the Arcade Learning Environment on a screen. The Robotroller and the Atari Devbox, together with an off-the-shelf camera and a desktop computer, constitute a system that can be used to study reinforcement learning algorithms in the physical world. We call the full system Physical Atari. In this paper, we detail the key decisions that make Physical Atari a robust and accessible platform. To make the system robust, we designed the Robotroller so that all movement is done through bearings, which reduces wear. Additionally, we wrote software that monitors the state of the servos at a high frequency and intervenes to limit stress. To make the system accessible, we used affordable off-the-shelf components and parts that can be manufactured using consumer 3D printers. Physical Atari can be built for under $1,000 and has been used for weeks of non-stop reinforcement learning experiments without any mechanical failures. We used it to validate that reinforcement learning algorithms can learn directly on robots and show that even small distribution shifts between learning and deployment can significantly degrade the performance of policies. Our results underscore the importance of on-device adaptation for strong performance on robots.

In semiconductor manufacturing, lithography projects circuit layouts onto silicon wafers through an optical mask. As circuit features shrink below the wavelength of light, optical diffraction causes the printed patterns to deviate from their intended layouts. Inverse Lithography Technology (ILT) addresses this challenge by generating optimized masks that enhance the fidelity of pattern transfer onto wafers. While ILT resembles an image synthesis task, its reliance on explicit physical metrics for mask evaluation limits the applicability of existing generative models. We introduce LithoGRPO, an ILT framework that integrates the flow-matching paradigm with GRPO-based reinforcement learning (RL) fine-tuning, enabling efficient exploration of diverse masks for a given target layout. Unlike purely generative or optimization-based approaches, RL in LithoGRPO exploits the explicitly defined, physics-based reward function of ILT, enabling optimization under complex, process-aware constraints. To the best of our knowledge, this is the first framework that unifies flow matching and RL for mask optimization. To improve RL sampling efficiency, we propose a fast shot-counting algorithm for manufacturability evaluation, achieving over 130x speedup while preserving the mask ranking of the traditional shot-count metric. Extensive experiments demonstrate that LithoGRPO achieves state-of-the-art performance over both optimization-based and learning-based methods, while maintaining efficient mask generation.

Robotics Wire Arc Additive Manufacturing (WAAM) is governed by complex and nonlinear process dynamics coupling thermal field to the build geometry. The process may be regarded as a multi-input/multi-output dynamical system with welding torch speed and wire feed rate as inputs and weld bead deposition height and width as outputs. In this paper, we use the input/output data to learn a data-driven model and use it for weld planning and control. We show that a simple recurrent neural network architecture and one-step-ahead predictive control can improve the process performance in terms of height and width consistency. To account for the changing thermal conditions during the printing process, we update the learning model using prediction error from the previous layer. This adaptation step further improves the prediction accuracy and controller performance. Experiments on a robotic WAAM testbed with integrated line-scanner feedback significant improvements in height and width consistency compared to constant input and static model baselines. The proposed learning and adaptation framework provides a practical pathway toward robust, data-driven regulation of additive manufacturing processes.

This paper presents a magnet-based robotic skin that integrates a multilayer soft lattice with distributed Hall-effect sensor arrays and a tactile super-resolution model. External contact forces are converted to magnetic field changes by embedded permanent magnets, and the lattice spreads these changes across the sensing domain. This gives each sensor a large, overlapping receptive field and enables a large sensing area with minimal blind spots. Lattice parameters are tunable, enabling joint adjustment of mechanical compliance and transduction characteristics. An implicit modeling workflow and selective laser sintering (SLS) 3D printing support rapid fabrication of conformal, high-complexity structures. A convolutional neural network trained on experimental measurements estimates contact location and normal force in real time. Experiments validate localization accuracy and indicate scalability to larger surfaces, suggesting applicability to whole-body robotic skin and safe human-robot interaction.

Light-based advanced manufacturing increasingly requires programmable, closed-loop tools that translate human design intent into executable operations at small length scales. Yet a key bottleneck persists across robotic and manufacturing modalities: turning user intent into machine-readable objectives that are reliably executable. While micro-robotics offers versatile manipulation via optical actuation of fluids, mathematically tractable goal specification remains manual and hard to reuse. Here, we introduce Speak-to-Objective, a modular agentic pipeline that uses a conditioned Large Language Model (LLM) to translate spoken or written commands into fully differentiable objective functions for assembling microparticles in a constraint-aware inverse solver (SLSQP) and on an experimental optofluidic platform. The approach employs a compact loop - perceive -> compose -> propose -> act -> report & learn - that treats the objective as the interface between intent and actuation, separating what to assemble or pattern from how to actuate, while learning from user feedback. The pipeline composes geometry, spacing, and assignment/topology terms to generate robust descriptive objectives that assemble from partial traces and recover after perturbations, as well as explicit objectives for precise placement, all in an actuator-agnostic fashion. Using laser-induced thermoviscous flows as the physical actuation modality, we demonstrate natural-language-programmable, light-based microscale assembly of particle patterns in a microfluidic environment. Beyond its immediate impact on programmable microassembly, and using laser-induced optofluidic actuation as a reduced-complexity experimental platform, our work points toward self-driving, AI-assisted optical manufacturing platforms in which natural language, differentiable objectives, and laser-based actuation are coupled into a reusable digital workflow.

Federated learning (FL) has broadened the horizon for multivariate time series anomaly detection (MTSAD). However, benchmarking such anomaly detection methods within FL paradigm poses data-centric challenges. The existing datasets do not counteract these challenges since they do not simultaneously provide sufficient scale, accurate labels, and freedom from common flaws. In addition, the role of cyclic process behavior, which is common in discrete industrial automation, remains underexplored for MTSAD for the current state of research. This paper aims to shed more light on the literature and address these gaps by introducing a dataset designed with cyclic dynamics arising from the repetitive nature of discrete automation processes and evaluates selected MTSAD methods on both the proposed dataset and a public benchmark dataset.

RocketSmith is an agentic system which intelligently automates the DFAM process for the development of high powered rockets suitable for launch. The system utilizes a large language model to orchestrate the execution of software tools to validate design characteristics such as flight stability and generate the parametric design components for the rocket assembly. A collection of subagents and skills enable optimization workflows of flight parameters via iteration in both zero-shot and human-in-the-loop workflows. With this system, four distinct high power rockets with various motor and assembly configurations were developed utilizing the unique design capabilities of additive manufacturing. These assembly components were fabricated using various FDM printers, manually evaluated for flight readiness, and flight tested at a launch event. From these tests, all rockets achieved a stable launch and two of the four rockets were successfully recovered in reflyable condition. The altimeter data validated that the rockets achieved an altitude 80% of the expected apogee predicted by the agentic system, establishing consistency between simulation and experimentation.

Design for manufacturing plays a critical role in advanced aeroengine development, where complex components necessitate careful consideration of manufacturability. However, current practices in pipe routing remain largely decoupled from down-stream manufacturing, leading to labor-intensive, trial-and-error iterations to achieve manufacturable designs. To address this problem, this study proposes the Frenet-based pipe routing optimization (FPRO) framework, a manufacturability knowledge-integrated reinforcement learning approach for free-form pipe design in aeroengines. FPRO formulates the routing problem as a boundary value problem in the Frenet frame. In this framework, the pipe path is represented by curvature and torsion profiles, which are generated using cubic Hermite interpolation. To integrate design and manufacturing, domain-specific manufacturing knowledge is embedded as constraints on the permissible ranges of curvature and torsion. The path optimization is performed using the proximal policy optimization algorithm with stochastic exploration and a stage-guided reward mechanism. A unified mapping formulation then translates the optimized path into motion trajectories for the bending die, enabling direct fabrication on a six-axis free-bending machine. Experimental results demonstrate that FPRO consistently generates collision-free, manufacturable paths with smoother geometric profiles compared to Cartesian-based methods. It also achieves faster convergence and superior performance in terminal alignment, path length, obstacle avoidance, and manufacturability compared to state-of-the-art reinforcement learning baselines. Real-world validation confirms the close geometric correspondence between the manufactured pipe and its digital design, validating the practical feasibility of FPRO.

This paper demonstrates the computational design of soft elastomeric pneumatic actuators using nonlinear topology optimization. An existing density- and porohyperelasticity-based topology optimization framework was extended from 2D to 3D and used to generate two manufacturable actuator designs, which were then studied numerically and experimentally. For both designs, the objective was to maximize the bending response for a prescribed actuation pressure under two different allowable strain limits. A key advantage of the employed topology optimization framework is that it can consistently, during the optimization, account for the very large deformations induced upon pressurization. The two optimized 3D designs were fabricated using stereolithography and experimentally tested to validate their performance.

Automatic generation of computer-aided design (CAD) models is a core technology for enabling intelligence in advanced manufacturing. Existing generation methods based on large language models (LLMs) often fall short when handling complex CAD models characterized by long operation sequences, diverse operation types, and strong geometric constraints, primarily because reasoning chains break and effective error-correction mechanisms are lacking. To address this problem, this paper proposes a memory-augmented reinforcement learning framework for CAD generation agents. The framework encapsulates the underlying geometric kernel into a structured toolchain callable by the agent and builds a closed-loop mechanism of design intent understanding, global planning, execution, and multi-dimensional verification. It also designs a dual-track memory module consisting of a case library and a skill library, and proposes a dynamic utility retrieval algorithm. By introducing reinforcement learning into retrieval and policy optimization, the agent can effectively avoid retrieval traps in which examples are semantically similar but geometrically infeasible, enabling online self-correction and continual evolution without additional large-scale annotated data. Experiments show that the proposed method significantly improves both the success rate and geometric consistency on complex CAD model generation tasks.

In sales and marketing, customer segmentation is an important tool for formulating strategies for customer treatment and supply chain management. Most segmentation implementations rely on limited criteria, such as recency, frequency, and monetary (RFM) modeling, which often fail to capture complex business interactions. In this work, we design and evaluate a dynamic multi-criteria decision-making (MCDM) method in a business-to-business (B2B) manufacturing context by 1) extending RFM to dimensions of stability and growth, 2) integrating an adaptive and analytical hierarchical process to match business objectives, and 3) evaluating multivariate time-series clustering models. We then measure customer stability, tracking between-segment transitions, and volatility over time, and apply a graph-based consensus model to further strengthen the analysis. We test the efficacy of the proposed method using a real-world manufacturing company dataset to segment more than 3,000 B2B customers, showing strong robustness to temporal shifts. The implementation enables domain experts with preferential analytics to devise their strategies, providing effective decision support for B2B customer segmentation.

In dynamic flow fields, various animals exhibit remarkable odor search capabilities despite relying on stochastic detections. Interestingly, there exists an optimal time window for integrating these detections that maximizes search efficiency. To understand the underlying mechanism, we investigate the navigation performance of Reinforcement Learning (RL) agents in unsteady flows under varying memory lengths and flow conditions. Without any predefined models, the agents develop a flow-assisted casting strategy and adaptively adjust both the geometry of their search trajectories and the concentration threshold for initiating casting to maximize the success rate. The agent's average speed toward the odor source exhibits a non-monotonic dependence on memory length, which can be explained by the "sector-search" model.

Task allocation in smart manufacturing systems needs to operate under decentralized decision-making, dynamic workloads, and shared resource constraints. In circular manufacturing settings, these challenges are further intensified by the need to balance operational efficiency with resource and energy sustainability. While learning-based approaches have been explored, many focus on predicting absolute performance metrics that do not necessarily translate into improved allocation outcomes, since decentralized assignment is governed by the relative ordering of candidate machines. This work proposes an Edge-AI-driven decentralized task allocation framework based on ranking-aware negotiation, where lightweight decision intelligence is embedded at the machine level to enable low-latency coordination without centralized control. The framework is developed progressively: a resource-aware heuristic first establishes the decentralized bidding structure, an Edge-AI-based regression model then provides learned local bid approximation, and a ranking-aware formulation finally reshapes the learning objective to align with the ordering-based nature of winner selection. Each machine evaluates incoming tasks using local information, including processing capability, queue state, and resource contention. The framework is evaluated via discrete-event simulation under high-load and tight-deadline scenarios using delay, deadline violations, throughput, and energy consumption. Results show improved delay and deadline adherence under high load, and enhanced energy efficiency under tighter constraints, leading to more resource-efficient operation aligned with circular manufacturing objectives. These findings demonstrate that aligning learning objectives with decentralized decision structures is critical for effective negotiation-driven task allocation.

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.

In cloud manufacturing, unmanned aerial vehicles (UAVs) can support both product collection and mobile edge computing (MEC). This joint operation forms a hybrid scheduling problem, where physical logistics decisions are coupled with computational task scheduling. In this paper, UAVs collect finished products from manufacturing stations and transport them back to a central depot. Meanwhile, computational tasks generated by industrial sensor devices at these stations are processed locally, at UAVs, or offloaded via UAVs to the cloud. This coupling makes the problem challenging. A UAV can provide MEC services only during its service window at a station, so routing decisions directly determine when UAV-assisted offloading is available. Routing decisions also affect the UAV energy budget and the availability of onboard computing and communication resources for computational task execution under task deadline constraints. To address this, we propose an agentic-AI-assisted optimization framework with two components. First, we develop an agentic AI that combines large language models, retrieval-augmented generation, and chain-of-thought reasoning to translate user input into an interpretable mathematical formulation for the hybrid scheduling problem. Second, we design a hierarchical deep reinforcement learning approach based on proximal policy optimization (PPO), where the upper layer learns UAV routing and the lower layer optimizes per-slot task execution and resource allocation. Simulation results show that the proposed framework yields more consistent formulations, while the hierarchical PPO achieves full product collection in 99.6% of the last 500 episodes and maintains a 100% deadline satisfaction rate, with more stable performance than the advantage actor-critic approach.

Assembling objects from parts requires understanding multimodal instructions, linking them to 3D components, and predicting physically plausible 6-DoF motions for each assembly step. Existing datasets focus on simplified scenarios, overlooking shape complexities and assembly trajectories in industrial assemblies. We introduce AssemblyBench, a synthetic dataset of 2,789 industrial objects with multimodal instruction manuals, corresponding 3D part models, and part assembly trajectories. We also propose a transformer-based model, AssemblyDyno, which uses the instructional manual and the 3D shape of each part to jointly predict assembly order and part assembly trajectories. AssemblyDyno outperforms prior works in both assembly pose estimation and trajectory feasibility, where the latter is evaluated by our physics-based simulations.

Graph-based machine learning has emerged as a promising approach for manufacturability analysis by learning directly from CAD models represented as Boundary Representations (B-reps), exploiting both surface geometry and topological connectivity. However, purely geometric representations often lack the process-specific semantics required for accurate manufacturability prediction: many manufacturing factors, such as surface roles or bend intent, are not explicitly encoded in shape alone and are difficult for data-driven models to infer reliably. We propose a hybrid approach that addresses this challenge by enriching B-rep attributed adjacency graphs with manufacturing features recognized through a rule-based module. Applied to sheet metal bending, recognized features, such as bend characteristics, flange lengths, and surface roles are integrated as node attributes, concentrating the learning signal on process-relevant geometric patterns. Experiments on both a large-scale synthetic manufacturability benchmark and a real-world industrial dataset with measured bending times, one of the first such validations on genuine production data, demonstrate that combining domain knowledge with graph-based learning improves prediction accuracy across both tasks. The results demonstrate that hybrid modeling offers a feasible and effective path toward deployable tools for manufacturability assessment and effort estimation in industrial CAD environments.

Robotic manipulation of flexible objects is widely required in both industrial and service applications. Among such objects, paper-like materials exhibit distinct mechanical characteristics compared to cloth, being more sensitive to compressive stress, where minor variations in physical properties can significantly affect grasping. This study systematically investigates grasping strategies for paper-like materials using a universal soft gripper by exploiting environmental constraints. Based on manipulation primitives employed in existing grasping strategies, we proposed systematic grasping strategies for flexible materials by exploiting environmental constraints and analyzed their mechanical and kinematic models. To investigate the influence of materials and working conditions on grasping, an evaluation system for measuring grasping force and success rate was defined and experimentally evaluated. Finally, we summarized the specific workspaces and characteristics of different strategies that can satisfy various task requirements and lead to potential applications in household service robots for grasping planar flexible objects.

Large language model (LLM)-based AI agents are increasingly deployed in manufacturing environments for analytics, quality management, and decision support. These agents demonstrate statistical fluency with domain terminology but lack grounded understanding of operational semantics -- the relational structure that connects equipment identifiers, process parameters, failure codes, and regulatory constraints within a specific production context. This paper identifies and formalizes the semantic training gap: a structural disconnect between how AI systems acquire domain vocabulary through training and how manufacturing operations define meaning through ontological relationships. We demonstrate that this gap causes operationally incorrect outputs even when model responses are linguistically precise, and that in multi-agent configurations it produces a compounding failure mode we term semantic drift. To close this gap, we present an architecture that embeds manufacturing ontology directly into the AI tool layer as a typed relational configuration, enforcing semantic constraints at runtime rather than relying on model training. The architecture is formalized as a three-operation interface contract -- resolve, contextualize, annotate -- with invariants enforced by an AIOps orchestration layer. In a controlled experiment across six industry configurations (72 tool invocations using Qwen3-32B), unconstrained tool parameters produced a 43% hallucination rate for domain identifiers; ontology-grounded parameters reduced this to 0%. We validate the approach through a digital twin analytics platform demonstrating that a single codebase with domain-specific ontology configurations eliminates tool-call hallucination and achieves cross-domain configurability without application code changes.

We present FrameTwin, a curve-anchored Gaussian alignment framework that uses sparse-view images to close the control loop for adaptive wireframe 3D printing. Our key idea is to capture the deformation of thin wireframe structures from sparse-view images using Gaussian kernels anchored to parametric curves, yielding a compact and geometry-aware encoding that explicitly captures strut topology. Driven by a differentiable rendering pipeline, FrameTwin estimates a neural deformation field that aligns the partially printed target model with the deformed structure observed during fabrication, where the optimized curve-Gaussian representation serves as a digital twin of the evolving wireframe. Unlike general Gaussian-splatting approaches, our formulation constrains kernel placement along parametric curves, substantially reducing the ambiguity inherent in sparse-view observations of thin structures. The resultant deformation-field alignment enforces global consistency across all struts. By using the estimated deformation field to blend the distorted printed geometry with the remaining unprinted geometry, FrameTwin enables adaptive updates to future printing trajectories. We demonstrate that FrameTwin can robustly capture and compensate for deformation in wireframe models fabricated using a robotized 3D printing system.

This paper introduces a low-cost experimental mockup to simulate the laser cutting process of containers in nuclear decommissioning. It is composed of a three-axis table supporting a cuboid container with ultraviolet-sensitive faces, a six-degree-of-freedom serial manipulator holding an ultraviolet torch that simulates the laser, and a visual system based on cameras and fiducial markers. The system employs a constrained task-space adaptive motion controller that compensates for inaccurate parameters and eliminates the need to calibrate the system. Furthermore, as the motion controller explicitly accounts for geometric constraints, the robot reactively avoids collisions with obstacles while handling the ultraviolet torch. To improve the tracking of the laser-cutting path, we control the ultraviolet beam, which requires only four degrees of freedom, instead of the full end-effector pose. Experiments show that, despite an initially uncalibrated system, the overall system is capable of tracking different trajectories with an overall mean accuracy of 3.9 (sd 2.5) mm when the end-effector pose is controlled and 2.4 (sd 1.3) mm when the ultraviolet beam is controlled.

Advanced manufacturing technologies allow for the production of intricate parts featuring high shape complexity and spatially-varying material composition. Data fusion of point clouds with chromatic attributes provides 4D point clouds, a compact and informative representation that encodes both shape and material information. In this paper, we present a registration-free framework for Simultaneous Monitoring of shApe and Color (SMAC) via 4D point clouds. The proposed framework leverages Laplace-Beltrami operator spectral properties to capture and monitor geometric features and the relationship between shape and surface color. A combined monitoring scheme is proposed to effectively detect shape deformations and color anomalies, along with a spatially-aware post-signal diagnostic procedure to determine the source of change and localize color anomalies. Importantly, neither component relies on registration or mesh reconstruction, eliminating error-prone and computationally expensive preprocessing steps. A Monte Carlo simulation study and a case study on functionally graded materials demonstrate that SMAC achieves effective detection performance, particularly for subtle defects, while providing diagnostic capabilities to identify the source and location of anomalies.

As time-to-market is crucial in the Integrated Circuit (IC) industry, speeding up layout manufacturability verifi-cation is essential. Chemical-Mechanical Polishing (CMP) plays a vital role in IC fabrication but is significantly influenced by Layout-Dependent Effects (LDE). An accurate and efficient CMP model enables design teams to correct surface unevenness before fabrication, reducing costs and accelerating the design phase. However, existing models often rely on Density Step Height (DSH) modeling, which is time-consuming for calibration and requires substantial hardware resources for fine-grained predictions. In this paper, we propose combining the advantages of two surface analysis techniques, White Light Interfer-ometry (WLI) and Atomic Force Microscopy (AFM), to train a deep learning model. This model aims to predict full-chip post-CMP nanotopography with nanometer-scale accuracy. Our deep learning model is based on a Convolutional Neural Network (CNN) and follows a two-step pipeline. The model is trained on each technique separately, resulting in a detailed full-chip CMP model.

We introduce an elastic-driven self-folding approach that fabricates robots directly from flat 3D-printed conductive PLA nets. Elastic bands routed through printed hooks store energy that folds the sheet into programmed 3D geometries, while the flat state allows accurate placement of electronics and magnets before deployment. The same substrate doubles as electrodes for capacitive touch and supports a reusable platform I/O palette with Hall sensors and eccentric rotating mass (ERM) motors for docking detection and vibration actuation. We also derive a closed-form folding model that balances hinge stiffness with elastic band moment to predict equilibrium fold angles; experiments validate the model and yield a design map linking hinge thickness, band size, and hook spacing to target angles. Using this workflow we realize multiple polyhedral modules and demonstrate three applications: a cube that highlights the potential of self-folding for scalable modular robot collectives, a deployable gripper, and a tendon-driven finger. The method is low cost, stimulus-free, and integrates actuation and sensing.

Additive manufacturing (AM) continues to transform modern manufacturing by enabling flexible, on-demand production of complex geometries across diverse industries. Fused filament fabrication (FFF) has extended AM to laboratories, classrooms, and small production environments, but this accessibility shifts process-planning responsibility to users who may lack manufacturing expertise. A syntactically valid slicer profile can still encode thermally or geometrically harmful settings, and subtle G-code edits can alter extrusion, cooling, or adhesion before a print begins. Pre-print G-code screening catches accidental or adversarial machine-program errors before material or machine time is wasted. This paper proposes LLM-ADAM as a generalizable LLM framework for pre-print anomaly detection in AM. The framework decomposes the task into three roles: Extractor-LLM maps a G-code file to a structured process-parameter schema; Reference-LLM converts printer and material documentation into aligned operating ranges; and Judge-LLM interprets a deterministic deviation table and G-code evidence to decide whether a part is non-defective or belongs to an anomaly class. Printers, materials, and LLM backbones are interchangeable test conditions, not fixed assumptions. We evaluate the framework on an N=200 FFF G-code corpus spanning two desktop printer families, two materials, and five classes including non-defective, under-extrusion, over-extrusion, warping, and stringing. The best framework configuration reaches 87.5% accuracy, compared with 59.5% for the strongest engineered single-LLM baseline. The results show that structured decomposition, rather than backbone strength alone, is the dominant source of improvement, with defect classes identified at or near ceiling for leading configurations while residual errors concentrate on conservative false alarms for non-defective samples.

Foundation models, particularly large language models, are increasingly integrated into agent architectures for industrial tasks such as decision support, process monitoring, and engineering automation. Yet evidence on their purposes, capabilities, and limitations remains fragmented across domains. This work examines how mature foundation-model-based agent systems are in industrial contexts, how their functional profile differs from conventional agent systems, and which limitations persist. A systematic literature survey following the PRISMA 2020 guideline is presented, screening 2,341 publications and synthesising a corpus of 88 publications through a structured coding scheme. The results show that reported systems are predominantly at prototype and early validation stages (75.0% at TRL 4-6), with deployment-oriented evidence remaining rare (9.1%). Operational goals are most frequently positioned in user assistance, monitoring, and process optimisation, while conventional production-control purposes such as planning and scheduling are less prominent. Compared with an established baseline for industrial agent systems, the capability profile reveals substantial gains in human interaction (+37%) and dealing with uncertainty (+35%), but a pronounced deficit in negotiation (-39%). The most widely reported limitations concern lack of generalization, hallucination and output instability, data scarcity, and inference latency. A working definition of foundation-model-based industrial agents is also proposed, bridging conventional agent theory, automation-engineering standards, and the foundation-model paradigm.

This work presents a knowledge-driven decision-support system that integrates structured defect knowledge with LLM-based reasoning to provide explainable defect diagnosis and mitigation guidance in manufacturing, using LPBF as a representative, safety-critical case study. The proposed ontology-integrated LLM-based decision support system for LPBF defect analysis and mitigation guidance is built on a knowledge base containing 27 known LPBF defect types organized into hierarchical categories and causal relationships. The developed system supports fuzzy natural language queries for systematic knowledge retrieval, literature-supported explanation of defects, and guidance on defect causes and mitigation strategies derived from encoded process knowledge. Furthermore, a multimodal image-assessment module based on foundation models enables descriptor-guided interpretation of representative microscopic defect images through semantic alignment scoring. The proposed framework was evaluated through qualitative comparisons with general-purpose vision-language models, an ablation study, and an inter-rater reliability analysis. Evaluation on the literature-derived dataset showed that the fully integrated configuration outperformed the other three evaluated system configurations, achieving a macro-average F1 score of 0.808. Additionally, inter-rater reliability analysis using Cohen's kappa indicated substantial agreement between the model outputs and the literature-derived reference labels. These findings suggest that ontology-guided knowledge representation can improve the consistency, interpretability, and practical usefulness of LLM-assisted LPBF defect analysis.

Autonomous science is transforming how we discover materials and chemical systems for advanced energy technologies. However, many initially promising systems never reach deployment. This "valley of death" stems from optimization that prioritizes laboratory metrics over industrial viability. We propose a new strategy: "born-qualified" autonomous development, which embeds manufacturability, cost, and durability constraints from the outset. This approach is enabled by four pillars, including the development of multi-objective metrics, causal models, a modular infrastructure, and embedding manufacturing in the discovery loop. Realizing this vision will require sustained, community-wide commitment, but the potential return on that investment is commensurate with the scale of the challenge.

This comprehensive review examines the evolution and the current state of the art in three-dimensional (3D) reconstruction techniques in manufacturing applications. The analysis covers both traditional approaches and emerging deep learning methods, showing a critical research gap in unified 3d reconstruction frameworks. Through systematic review of 106 recent publications, we classify reconstruction techniques into three primary categories: data acquisition, point cloud generation, post-processing and applications. Non-contact methods, particularly structured light scanning and stereo vision, have shown significant adoption in manufacturing, with 47% of surveyed applications focusing on quality inspection. The integration of deep learning has enhanced reconstruction accuracy and processing speed, particularly in feature extraction and matching. Key applications span design and development (13%), machining (8%), process (17%), assembly (22%), and quality inspection (40%). While current technologies achieve sub-millimeter accuracy in controlled environments, challenges persist in handling reflective surfaces and dynamic environments. Our findings indicate a trend toward hybrid systems combining multiple sensor types and processing methods to overcome individual limitations. This survey provides a structured framework for understanding current capabilities and future directions in manufacturing-focused 3D reconstruction.

The technological maturity of in situ inspection and monitoring methods in additive manufacturing is steadily increasing, enabling more efficient and practical qualification procedures. In this context, image segmentation of powder bed images in Laser Powder Bed Fusion (L-PBF) has been investigated by various authors, leveraging both edge detection and machine learning approaches to identify deviations from nominal geometry. Despite these developments, several challenges remain, including the sensitivity of segmentation performance to industrial illumination conditions and layer-to-layer variability in pixel intensity patterns. The study addresses these limitations by proposing a graph-augmented segmentation approach. The underlying principle consists of preserving the geometrical information at a global level rather than at pixel-wise level, modeling dependencies and relational information among spatial regions with a Graph Neural Network bottleneck embedded into a U-Net architecture. This allows enhancing the consistency and accuracy of the geometry reconstruction in the presence of spatial and layer-wise photometric variability systematically faced in real data. The method is evaluated against benchmark techniques for the in situ reconstruction of lattice structures produced by L-PBF, demonstrating its potential as a scalable solution for robust in situ inspection and geometric verification in industrial environments.

Accurately estimating friction coefficients between arbitrary material pairs is critical for robotics, digital fabrication, and physics-based simulation, but exhaustive pairwise testing scales quadratically with the number of materials. We introduce a proxy-based modeling framework that approximates any pairwise friction $f(A,B)$ from a small, fixed set of proxy materials $C=[c_1,\dots,c_k]$ by learning a per-material embedding $z_A = g(f(A,c1),\dots,f(A,ck))$ and a fusion function $p$ such that $f(A,B)\approx p\big(z_A,z_B\big)$. We present deterministic and probabilistic realizations of $g$ and $p$, procedures for selecting diverse proxy sets, and mechanisms for handling missing or noisy proxy measurements. The learned embeddings are compact, interpretable, and enable calibrated uncertainty estimates for downstream decision making. On simulated and measured friction datasets, our approach achieves high predictive accuracy, robust performance with partial observations, and substantial experimental savings by significantly reducing pairwise testing.

Industrial robots are widely used in manufacturing, yet most manipulation still depends on fixed waypoint scripts that are brittle to environmental changes. Learning-based control offers a more adaptive alternative, but it remains unclear whether such methods, still mostly confined to laboratory demonstrations, can sustain hours of reliable operation, deliver consistent quality, and behave safely around people on a live production line. Here we present Learning-Augmented Robotic Automation, a hybrid system that integrates learned task controllers and a neural 3D safety monitor into conventional industrial workflows. We deployed the system on an electric-motor production line to automate deformable cable insertion and soldering under real manufacturing constraints, a step previously performed manually by human workers. With less than 20 min of real-world data per task, the system operated continuously for 5 h 10 min, producing 108 motors without physical fencing and achieving a 99.4% pass rate on product-level quality-control tests. It maintained near-human takt time while reducing variability in solder-joint quality and cycle time. These results establish a practical pathway for extending industrial automation with learning-based methods.

The recent emergence of planar transport systems necessitates re-evaluation of Flexible Manufacturing Systems (FMS) to address the simultaneous scheduling of internal logistics and production operations. By operating on a tile-based planar grid, these systems allow independent movers full two-dimensional freedom, mitigating inefficiencies inherent to traditional sequential lines. This paper applies a planar FMS framework to a real-world use case in the pharmaceutical industry: the automated production of personalized drugs. Implementing this system requires solving optimization problems at both tactical and operational levels. The tactical level involves decisions regarding production line layout and the positioning of drug dispensers. A Mixed-Integer Quadratic Programming model is utilized for the packing problem to exploit drug co-occurrence patterns found in historical patient data. Subsequently, we solve the placement problem - a bi-level problem combining an assignment problem with Shortest Hamiltonian paths with neighborhoods - to arrange dispensers in a layout minimizing expected travel distances. The operational level is encountered daily, scheduling individual movers to process new orders as quickly as possible. This scheduling problem is formulated using Constraint Programming, modeling movers as reservoir resources to ensure order completeness, complemented by a routing phase using an iterative conflict-resolution mechanism and DAG-based reasoning to convert schedules into conflict-free paths. Evaluation using real-world prescription data for 40 drugs shows the framework scales efficiently across several layout topologies for up to 500 orders, with schedules that are highly effective and computationally tractable for daily operations.

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.

Functional magnetic composites capable of large deformation, load bearing, and multifunctional motion are essential for next-generation adaptive soft robots. Here, we present muscle-inspired magnetic actuators (MMA), additively manufactured from a thermoplastic/permanent magnet polyurethane/Nd2Fe14B (TPU/MQP-S) composite using laser powder bed fusion (LPBF). By tuning the laser-energy scale between 1.0 and 3.0, both mechanical stiffness and magnetic response are precisely controlled: the tensile strength increases from 0.28 to 0.99 MPa while maintaining 30-45% elongation at break. This process enables the creation of 0.5 mm-thick flexural hinges, which reversibly bend and fold under moderate magnetic fields without damage. Two actuator types are reported showing the system versatility. The elongated actuator with self-weight of 1.57 g, magnetized in its contracted state, achieves linear contraction under a 500 mT field, lifting 50 g (32x its own weight) and sustaining performance over at least 50 cycles. Equipped with anisotropic frictional feet, it supports movement of a magnetic crawling robot that achieves up to 100% locomotion success on textured substrates. The expandable actuator exhibits reversible opening and closing under a 300 mT field, reliably grasping and releasing different objects, including soft berries and rigid 3D printed geometries. It can also anchor in a tube while holding suspended 50 g loads. This work demonstrates a LPBF-based strategy to program both stiffness and magnetization within a single material system, enabling remotely driven, reconfigurable, and fatigue-resistant soft actuators. The approach opens new possibilities for force controlled, multifunctional magnetic soft robots for adaptive gripping, locomotion, and minimally invasive manipulation of biomedical tools.

Manufacturing industries are facing increasing product variability due to the growing demand for personalized products. Under these conditions, ensuring safety becomes challenging as frequent reconfigurations can lead to unintended hazardous behaviors. Multi-agent control architectures have been proposed to improve flexibility through decentralized decision-making and coordination. However, these architectures are based on predefined task models, which limit their ability to adapt task planning to new product requirements while preserving safety. Recently, large language models have been introduced into manufacturing systems to enhance adaptability, but reliability remains a key challenge. To address this issue, we propose a control architecture that leverages the flexibility of large language models while preserving safety on the manufacturing shop floor. Specifically, the proposed framework verifies large language model-enabled task allocations by using temporal logic and discrete event systems. The effectiveness of the proposed framework is demonstrated through a case study that involves a multi-robot assembly scenario, showing that unsafe tasks can be allocated safely before task execution.

Explaining Machine Learning (ML) results in a transparent and user-friendly manner remains a challenging task of Explainable Artificial Intelligence (XAI). In this paper, we present a method to enhance the interpretability of ML models by using a Knowledge Graph (KG). We store domain-specific data along with ML results and their corresponding explanations, establishing a structured connection between domain knowledge and ML insights. To make these insights accessible to users, we designed a selective retrieval method in which relevant triplets are extracted from the KG and processed by a Large Language Model (LLM) to generate user-friendly explanations of ML results. We evaluated our method in a manufacturing environment using the XAI Question Bank. Beyond standard questions, we introduce more complex, tailored questions that highlight the strengths of our approach. We evaluated 33 questions, analyzing responses using quantitative metrics such as accuracy and consistency, as well as qualitative ones such as clarity and usefulness. Our contribution is both theoretical and practical: from a theoretical perspective, we present a novel approach for effectively enabling LLMs to dynamically access a KG in order to improve the explainability of ML results. From a practical perspective, we provide empirical evidence showing that such explanations can be successfully applied in real-world manufacturing environments, supporting better decision-making in manufacturing processes.

Kirigami is an increasingly useful fabrication method to produce shape-programmable metamaterial structures. However, inverse design remains difficult because deployment is nonlinear, and feasible cut layouts must satisfy discrete compatibility rules, avoid overlap, and map one target shape to valid designs. We present RL-Kirigami, an inverse design framework that combines optimal-transport conditional flow matching (OT-CFM) with reinforcement learning to generate compatible ratio fields for compact reconfigurable parallelogram quad kirigami. A marching decoder enforces global geometric compatibility, and Group Relative Policy Optimization (GRPO) aligns the generator with nondifferentiable rewards for silhouette matching, feasibility, and ratio-field regularity. Across procedurally generated target shape instances, a single sample from the pretrained OT-CFM prior reached $94.2$ sIoU and outperformed solver baselines while reducing forward simulator evaluations from hundreds to 1. GRPO improved accuracy to $94.91$ sIoU and, with regularity included, reduced $\mathrm{TV}(\mathbf{x})$ from 0.95 to 0.81 while maintaining $94.83$ sIoU. Generated layouts were exported to DXF and laser-cut in $50~μ\mathrm{m}$ polymeric sheets to produce deployable prototypes in $8.0 \pm 1.0$ minutes per part. These results support a manufacturing-aware inverse design workflow for deployable kirigami metamaterials under hard geometric feasibility constraints.

Accurate thermal modeling in metal additive manufacturing (AM) is essential for understanding the process-structure-performance relationship. While prior studies have explored generalization across unseen process conditions, they often require extensive datasets, costly retraining, or pre-training. Generalization across different materials also remains relatively unexplored due to the challenges posed by distinct material-dependent thermal behaviors. This paper introduces a parametric physics-informed neural network (PINN) framework for zero-shot generalization across arbitrary materials without labeled data, retraining, or pre-training. The framework adopts a decoupled parametric PINN architecture that separately encodes material properties and spatiotemporal coordinates, fusing them through conditional modulation to better align with the multiplicative role of material parameters in the governing equation and boundary conditions. Physics-guided output scaling derived from Rosenthal's analytical solution and a hybrid optimization strategy are further incorporated to enhance physical consistency, training stability, and convergence. Experiments on bare plate laser powder bed fusion (LPBF) across diverse metal alloys, including both in-distribution and out-of-distribution cases, demonstrate effective zero-shot generalizability along with superior training efficiency. Specifically, the proposed framework achieved up to a 64.2% reduction in relative L2 error compared to the non-parametric baseline while surpassing its performance within only 4.4% of the baseline training epochs. Ablation studies confirm that the proposed framework's components are broadly applicable to other PINN-based approaches. Overall, the proposed framework provides an efficient and scalable material-agnostic solution for zero-shot thermal modeling, contributing to more flexible and practical deployment in metal AM.

This paper presents the design, modeling, and fabrication of 3D-printed, tendon-actuated continuum robots featuring a flexible, tapered backbone constructed from thermoplastic polyurethane (TPU). Our scalable design incorporates an integrated electronics base housing that enables direct tendon tension control and sensing via actuators and compression load cells. Unlike many continuum robots that are single-purpose and costly, the proposed design prioritizes customizability, rapid assembly, and low cost while enabling high curvature and enhanced distal compliance through geometric tapering, thereby supporting a broad range of compliant robotic inspection and manipulation tasks. We develop a generalized forward kinetostatic model of the tapered backbone based on Cosserat rod theory using a Newtonian approach, extending existing tendon-actuated Cosserat rod formulations to explicitly account for spatially varying backbone cross-sectional geometry. The model captures the graded stiffness profile induced by the tapering and enables systematic exploration of the configuration space as a function of the geometric design parameters. Specifically, we analyze how the backbone taper angle influences the robot's configuration space and manipulability. The model is validated against motion capture data, achieving centimeter-level shape prediction accuracy after calibrating Young's modulus via a line search that minimizes modeling error. We further demonstrate teleoperated grasping using an endoscopic gripper routed along the continuum robot, mounted on a 6-DoF robotic arm. Parameterized iLogic/CAD scripts are provided for rapid geometry generation and scaling. The presented framework establishes a simple, rapid, and reproducible pathway from parametric design to controlled tendon actuation for tapered, tendon-driven continuum robots manufactured using fused deposition modeling 3D printers.

Equipping robotic systems with the capacity to generate $\textit{ex novo}$ hardware during operation extends physical adaptability. Unlike modular systems that rely on discrete component integration pre- or post-deployment, we envision physical adaptation through continuous in-body development via hardware synthesis. Drawing inspiration from circulatory systems that redistribute mass and function in biological organisms, we utilize fluidics to restructure the material interface, a capability currently unmatched in robotics. Here, we realize this proof-of-concept hardware generation through a vascularized robotic composite designed for programmable material synthesis, demonstrated via receptogenesis - the on-demand construction of sensors. By coordinating the fluidic transport of precursors with external localized UV irradiation, we drove an $\textit{in situ}$ photopolymerization that chemically reconstructed the vasculature from the inside out. This reaction converted precursors with photolatent initiator into a solid dispersion of UV-sensitive polypyrrole in PETG, establishing a sensing modality validated by a characteristic decrease in electrical impedance. The newly synthesized sensor closed a local control loop in real time to regulate wing flapping in a moth-inspired robotic demonstrator. Our work is a proof-of-concept materials basis for $\textit{ex novo}$ hardware generation in a vascularized composite - a step towards situated robots adapting to environmental cues.

Human-machine interfaces in industrial automation need sensing modules that monitor operator actions and physiological state. This is important in factories, vehicles, machinery cabins, and human-robot collaboration, where workload, stress, fatigue, or reduced attention can affect safety. RGB monitoring is limited by low light, shadows, and privacy concerns, while thermal infrared imaging captures skin temperature dynamics without visible illumination. This paper studies thermal video as a contactless computer vision modality for estimating electrodermal activity (EDA), heart rate (HR), and breathing rate (BR), with the goal of supporting adaptive human-machine interfaces and operator-state awareness. We propose a signal-processing pipeline that tracks facial regions, aggregates thermal signals, and separates slow sudomotor trends from faster cardiorespiratory components. HR is estimated using orthogonal matrix image transformation (OMIT) across multiple facial regions, while BR is estimated from nasal and cheek thermal signals using spectral peak detection. We characterize 288 ROI-method configurations against contact references with lag-tolerant metrics using 31 sessions from the public SIMULATOR STUDY 1 (SIM1) driver monitoring dataset. The best fixed EDA configuration reaches a mean absolute correlation of $0.40 \pm 0.23$ against palm EDA, with individual sessions reaching $0.89$. BR estimation achieves $3.1 \pm 1.1$ bpm mean absolute error, while HR estimation yields $13.8 \pm 7.5$ bpm MAE, limited by the $7.5$ Hz thermal camera frame rate. The results show that thermal video provides useful respiratory and sudomotor cues, while revealing limitations caused by ROI selection, polarity changes, latency, and subject variability. These findings provide baseline design guidance for thermal computer vision as an auxiliary sensing layer in adaptive industrial HMI systems.

Typically, heuristic/trial-based approaches are used to design soft pneumatic grippers (SPGs). This paper presents a systematic topology optimization framework for developing SPGs. The design-dependent nature of actuating load is modeled using Darcy's law with an added drainage term. A 2D soft arm unit is then optimized as a compliant mechanism under pneumatic loading. To ensure the design is robust and manufacturable, the problem is formulated as a min-max optimization, where output deformations of blueprint and eroded designs are considered. A volume constraint is imposed on the blueprint part, while a strain-energy constraint is enforced on the eroded part. The Method of Moving Asymptotes is employed to solve optimization problems. The optimized 2D part is extruded suitably to generate a 3D unit. Ten such 3D units are assembled to create a gripper arm. Both the optimized 2D unit and the corresponding gripper arm outperform their conventional rectangular designs under pneumatic loading, demonstrating the efficacy of the proposed approach. The arms are fabricated using the SLA printing technique. Numerical and experimental results are compared at different pneumatic loads. Four 3D-printed arms are integrated with a supporting structure to form the SPG. The gripping action of the SPG is demonstrated on objects with different weights, sizes, structures, stiffnesses, and shapes.

Affective computing has matured rapidly in laboratory settings, yet no prior dataset combines (i) months-to-years of duration, (ii) a naturalistic workplace context, (iii) a stable small-team social structure, and (iv) a fully passive sensing protocol that survives institutional review. We introduce WELD, the first dataset to satisfy all four. WELD comprises 733,780 per-frame seven-class facial-expression probability vectors from 49 employees of a Chinese software company over 30.1 months (Nov 2021 - May 2024) -- the longest naturalistic in-the-wild emotion corpus and the only multi-year corpus supporting both within-individual longitudinal and within-team relational analyses on the same subjects. Data are released under a four-tier access model with only aggregated probabilities publicly downloadable. We validate the corpus by replicating three established phenomena (+43.1% weekend valence boost; 13:00-trough diurnal cycle; Shanghai 2022 lockdown effect d=-0.40), and report four novel findings: (1) variance decomposition attributes 19.3% of daily-valence variance to between-person differences and 29.8% to month seasonality -- a quantitative ceiling for future predictive models; (2) Hidden Markov decomposition reveals six emotional regimes with asymmetric negative-state dwell times (16-18 d vs 3 d); (3) leave-one-person-out turnover prediction reaches AUC=0.79 yet a Cox concordance index of only 0.52, exposing a metric-trap when AUC is reported without survival-aware baselines; (4) the corpus reveals systematic over-prediction of "angry" by an off-the-shelf FER model on neutral Asian faces (0.194 vs ~0.05 Western priors), making WELD valuable for FER fairness audits. A complex-systems analysis of the corpus appears as a companion preprint (arXiv:2510.16046).

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.