Manufacturing

Matching plays an important role in the logical allocation of resources across a wide range of industries. The benefits of matching have been increasingly recognized in manufacturing industries. In particular, capacity sharing has received much attention recently. In this paper, we consider the problem of dynamically matching demand-capacity types of manufacturing resources. We formulate the multi-period, many-to-many manufacturing resource-matching problem as a sequential decision process. The formulated manufacturing resource-matching problem involves large state and action spaces, and it is not practical to accurately model the joint distribution of various types of demands. To address the curse of dimensionality and the difficulty of explicitly modeling the transition dynamics, we use a model-free deep reinforcement learning approach to find optimal matching policies. Moreover, to tackle the issue of infeasible actions and slow convergence due to initial biased estimates caused by the maximum operator in Q-learning, we introduce two penalties to the traditional Q-learning algorithm: a domain knowledge-based penalty based on a prior policy and an infeasibility penalty that conforms to the demand-supply constraints. We establish theoretical results on the convergence of our domain knowledge-informed Q-learning providing performance guarantee for small-size problems. For large-size problems, we further inject our modified approach into the deep deterministic policy gradient (DDPG) algorithm, which we refer to as domain knowledge-informed DDPG (DKDDPG). In our computational study, including small- and large-scale experiments, DKDDPG consistently outperformed traditional DDPG and other RL algorithms, yielding higher rewards and demonstrating greater efficiency in time and episodes.

In a previous work (Elaarabi et al., 2025b), the Sequence Encoder for online dynamical system identification (Elaarabi et al., 2025a) and its combination with PINN (PINN-SE) were introduced and tested on both synthetic and real data case scenarios. The sequence encoder is able to effectively encode time series into feature vectors, which the PINN then uses to map to dynamical behavior, predicting system response under changes in parameters, ICs and BCs. Previously (Elaarabi et al., 2025b), the tests on real data were limited to simple 1D problems and only 1D time series inputs of the Sequence Encoder. In this work, the possibility of applying PINN-SE to a more realistic case is investigated: heating and early cooling of the thermo-stamping process, which is a critical stage in the forming process of continuous fiber reinforced composite materials with thermoplastic polymer. The possibility of extending the PINN-SE inputs to multimodal data, such as sequences of temporal 2D images and to scenarios involving variable geometries, is also explored. The results show that combining multiple encoders with the previously proposed method (Elaarabi et al., 2025b) is feasible, we also show that training the model on synthetic data generated based on experimental data can help the model to generalize well for real experimental data, unseen during the training phase.

Achieving agile and reconfigurable production flows in smart factories depends on online multi-robot task assignment (MRTA), which requires online collision-free and congestion-free route scheduling of transportation multi-robot systems (T-MRS), e.g., collaborative automatic guided vehicles (AGVs). Due to the real-time operational requirements and dynamic interactions between T-MRS and production MRS, online scheduling under partial observability in dynamic factory environments remains a significant and under-explored challenge. This paper proposes a novel communication-enabled online scheduling framework that explicitly couples wireless machine-to-machine (M2M) networking with route scheduling, enabling AGVs to exchange intention information, e.g., planned routes, to overcome partial observations and assist complex computation of online scheduling. Specifically, we determine intelligent AGVs' intention and sensor data as new M2M traffic and tailor the retransmission-free multi-link transmission networking to meet real-time operation demands. This scheduling-oriented networking is then integrated with a simulated annealing-based MRTA scheme and a congestion-aware A*-based route scheduling method. The integrated communication and scheduling scheme allows AGVs to dynamically adjust collision-free and congestion-free routes with reduced computational overhead. Numerical experiments shows the impacts from wireless communication on the performance of T-MRS and suggest that the proposed integrated scheme significantly enhances scheduling efficiency compared to other baselines, even under high AGV load conditions and limited channel resources. Moreover, the results reveal that the scheduling-oriented wireless M2M communication design fundamentally differs from human-to-human communications, implying new technological opportunities in a wireless networked smart factory.

We use fused deposition modeling (FDM) 3D printing as a case study of how manufacturing robots can use imperfect AI. In FDM, print configuration strongly affects output quality. Yet, novice users typically rely on default configurations, trial-and-error, or direct recommendations from generic AI models (e.g., ChatGPT). These strategies can produce complete prints, but they do not reliably meet specific objectives. We present a modular approach that treats an LLM as a source of tuning expertise. We embed this source of expertise within a Bayesian optimization loop. An approximate evaluator scores each candidate print configuration and returns structured diagnostics, which the LLM uses to propose natural-language adjustments that are compiled into machine-actionable guidance for optimization. On 100 Thingi10k parts, our LLM-guided loop achieves the best configuration on 78% objects with 0% likely-to-fail cases, while direct AI model recommendations are rarely best and exhibit 15% likely-to-fail cases. These results suggest that LLMs provide more value as constrained decision modules in optimization loops than as end-to-end oracles for print configuration selection. We expect this result to extend to broader LLM-based robot programming.

Industrial process control demands policies that are interpretable and auditable, requirements that black-box neural policies struggle to meet. LLM-driven heuristic synthesis offers an alternative: a language model iteratively proposes and refines human-readable Python controllers using rich behavioral feedback from a simulator. We study this form of programmatic policy search on hot steel rolling, a physics-simulated, multi-pass control problem with competing objectives and hard equipment constraints, and address three questions that arise once the search is run at scale: how to split a fixed budget of LLM iterations between restarting and refining, how to deploy the resulting pool of heuristics, and how to verify it. Treating each search run as a randomized algorithm, we find across 52 independent runs that runs of moderate length match the hindsight-optimal budget allocation, and that Luby-style universal restarts reach this regime without problem-specific tuning. Because each heuristic is cheap to simulate, a small portfolio selected per job outperforms the best single heuristic, also under cross-validation and on out-of-distribution operating conditions on which the best heuristic stalls. Finally, an automated audit pipeline combining static analysis, Z3 proofs, and property-based testing proves key safety properties for all 174 synthesized heuristics; the stall, which neither the search reward nor these properties reveal, shows that the specifications must also cover progress.

Unidirectional tapes surface roughness determines the evolution of the degree of intimate contact required for ensuring the thermoplastic molecular diffusion and the associated inter-tapes consolidation during manufacturing of composite structures. However, usual characterization of rough surfaces relies on statistical descriptors that even if they are able to represent the surface topology, they are not necessarily connected with the physics occurring at the interface during inter-tape consolidation. Thus, a key research question could be formulated as follows: Which roughness descriptors simultaneously enable tape classification-crucial for process control-and consolidation modeling via the inference of the evolution of the degree of intimate contact, itself governed by the process parameters?. For providing a valuable response, we propose a novel strategy based on the use of Rank Reduction Autoencoders (RRAEs), autoencoders with a linear latent vector space enforced by applying a truncated Singular Value Decomposition (SVD) to the latent matrix during the encoder-decoder training. In this work, we extract useful roughness descriptors by enforcing the latent SVD modes to (i) accurately represent the roughness after decoding, and (ii) allow the extraction of existing a priori knowledge such as classification or modelling properties.

Large Language Models-Cognitive Assistants (LLM-CAs) can enhance Quality Management Systems (QMS) in manufacturing, fostering continuous process improvement and knowledge management. However, there is no human-centred software architecture focused on QMS that enables the integration of LLM-CAs into manufacturing in the current literature. This study addresses this gap by designing a component-based architecture considering requirement analysis and software development process. Validation was conducted via iterative expert focus groups. The proposed architecture ensures flexibility, scalability, modularity, and work augmentation within QMS. Moreover, it paves the way for its operationalization with industrial partners, showcasing its potential for advancing manufacturing processes.

This study presents a geometric deep learning framework for predicting cold spray particle impact responses using finite element simulation data. A parametric dataset was generated through automated Abaqus simulations spanning a systematic range of particle velocity, particle temperature, and friction coefficient, yielding five output targets including maximum equivalent plastic strain, average contact plastic strain, maximum temperature, maximum von Mises stress, and deformation ratio. Four novel algorithms i.e. a GraphSAGE-style inductive graph neural network, a Chebyshev spectral graph convolution network, a topological data analysis augmented multilayer perceptron, and a geometric attention network were implemented and evaluated. Each input sample was treated as a node in a k-nearest-neighbour feature-space graph, enabling the models to exploit spatial similarity between process conditions during training. Three-dimensional feature space visualisations and two-dimensional contour projections confirmed the highly non-linear and velocity-dominated nature of the input-output relationships. Quantitative evaluation demonstrated that GraphSAGE and GAT consistently achieved R-square values exceeding 0.93 across most targets, with GAT attaining peak performance of R-square equal to 0.97 for maximum plastic strain. ChebSpectral and TDA-MLP performed considerably worse, yielding negative R-square values for several targets. These findings establish spatial graph-based neighbourhood aggregation as a robust and physically interpretable surrogate modelling strategy for cold spray process optimisation.

Silicon photonic devices often exhibit fabrication-induced variations such as over-etching, underetching, and corner rounding, which can significantly alter device performance. These variations are non-uniform and are influenced by feature size and shape. Accurate digital twins are therefore needed to predict the range of possible fabricated outcomes for a given design. In this paper, we introduce Gen-Fab, a conditional generative adversarial network (cGAN) based on Pix2Pix to predict and model uncertainty in photonic fabrication outcomes. The proposed method takes a design layout (in GDS format) as input and produces diverse high-resolution predictions similar to scanning electron microscope (SEM) images of fabricated devices, capturing the range of process variations at the nanometer scale. To enable one-to-many mapping, we inject a latent noise vector at the model bottleneck. We compare Gen-Fab against three baselines: (1) a deterministic U-Net predictor, (2) an inference-time Monte Carlo Dropout U-Net, and (3) an ensemble of varied U-Nets. Evaluations on an out-of-distribution dataset of fabricated photonic test structures demonstrate that Gen-Fab outperforms all baselines in both accuracy and uncertainty modeling. An additional distribution shift analysis further confirms its strong generalization to unseen fabrication geometries. Gen-Fab achieves the highest intersection-over-union (IoU) score of 89.8%, outperforming the deterministic U-Net (85.3%), the MC-Dropout U-Net (83.4%), and varying U-Nets (85.8%). It also better aligns with the distribution of real fabrication outcomes, achieving lower Kullback-Leibler divergence and Wasserstein distance.

Reliable classification of 3D-printed objects is essential for automating post-production workflows in industrial additive manufacturing. Despite extensive automation in other stages of the printing pipeline, this task still relies heavily on manual inspection, as the set of objects to be classified can change daily, making frequent model retraining impractical. Automating the identification step is therefore critical for improving operational efficiency. A vision model that could classify any set of objects by utilizing their corresponding CAD models and avoiding retraining would be highly beneficial in this setting. To enable systematic evaluation of vision models on this task, we introduce ThingiPrint, a new publicly available dataset that pairs CAD models with real photographs of their 3D-printed counterparts. Using ThingiPrint, we benchmark a range of existing vision models on the task of 3D-printed object classification. We additionally show that contrastive fine-tuning with a rotation-invariant objective allows effective prototype-based classification of previously unseen 3D-printed objects. By relying solely on the available CAD models, this avoids the need for retraining when new objects are introduced. Experiments show that this approach outperforms standard pretrained baselines, suggesting improved generalization and practical relevance for real-world use.

Over the past decade, Artificial Intelligence has significantly advanced, mostly driven by large-scale neural approaches. However, in the chemical process industry, where safety is critical, these methods are often unsuitable due to their brittleness, and lack of explainability and interpretability. Furthermore, open-source real-world datasets containing historical failures are scarce in this domain. In this paper, we investigate an approach for predicting failures in chemical processes using symbolic machine learning and conduct a feasibility study in the context of an ethylene oxidation process. Our method builds on a state-of-the-art symbolic machine learning system capable of learning predictive models in the form of probabilistic rules from context-dependent noisy examples. This system is a general-purpose symbolic learner, which makes our approach independent of any specific chemical process. To address the lack of real-world failure data, we conduct our feasibility study leveraging data generated from a chemical process simulator. Experimental results show that symbolic machine learning can outperform baseline methods such as random forest and multilayer perceptron, while preserving interpretability through the generation of compact, rule-based predictive models. Finally, we explain how such learned rule-based models could be integrated into agents to assist chemical plant operators in decision-making during potential failures.

Accurate fault detection in high-dimensional industrial environments remains a major challenge due to the inherent complexity, noise, and redundancy in sensor data. This paper introduces CLAIRE, i.e., a hybrid end-to-end learning framework that integrates unsupervised deep representation learning with supervised classification for intelligent quality control in smart manufacturing systems. It employs an optimized deep autoencoder to transform raw input into a compact latent space, effectively capturing the intrinsic data structure while suppressing irrelevant or noisy features. The learned representations are then fed into a downstream classifier to perform binary fault prediction. Experimental results on a high-dimensional dataset demonstrate that CLAIRE significantly outperforms conventional classifiers trained directly on raw features. Moreover, the framework incorporates a post hoc phase, using a game-theory-based interpretability technique, to analyze the latent space and identify the most informative input features contributing to fault predictions. The proposed framework highlights the potential of integrating explainable AI with feature-aware regularization for robust fault detection. The modular and interpretable nature of the proposed framework makes it highly adaptable, offering promising applications in other domains characterized by complex, high-dimensional data, such as healthcare, finance, and environmental monitoring.

The fundamental topology of manufacturing has not undergone a paradigm-level transformation since Henry Ford's moving assembly line in 1913. Every major innovation of the past century, from the Toyota Production System to Industry 4.0, has optimized within the Fordist paradigm without altering its structural logic: centralized mega-factories, located near labor pools, producing at scale. We argue that embodied intelligence is poised to break this century-long stasis, not by making existing factories more efficient, but by triggering phase transitions in manufacturing economic geography itself. When embodied AI capabilities cross critical thresholds in dexterity, generalization, reliability, and tactile-vision fusion, the consequences extend far beyond cost reduction: they restructure where factories are built, how supply chains are organized, and what constitutes viable production scale. We formalize this by defining a Capability Space C = (d, g, r, t) and showing that the site-selection objective function undergoes topological reorganization when capability vectors cross critical surfaces. Through three pathways, weight inversion, batch collapse, and human-infrastructure decoupling, we show that embodied intelligence enables demand-proximal micro-manufacturing, eliminates "manufacturing deserts," and reverses geographic concentration driven by labor arbitrage. We further introduce Machine Climate Advantage: once human workers are removed, optimal factory locations are determined by machine-optimal conditions (low humidity, high irradiance, thermal stability), factors orthogonal to traditional siting logic, creating a production geography with no historical precedent. This paper establishes Embodied Intelligence Economics, the study of how physical AI capability thresholds reshape the spatial and structural logic of production.

Micro-milling spindles require high rotational speeds where conventional rolling element bearings face limitations such as friction and thermal expansion. Active magnetic bearings (AMBs) address these challenges by providing non-contact and lubrication-free operation at ultra-high speeds with the ability to actively regulate spindle dynamics. The existing literature on AMB spindles has mainly reported specific prototype realizations or control system implementations for specific spindle dynamics. Consequently, design knowledge remains fragmented across isolated successful studies. This paper addresses this gap by presenting a systematic and iterative framework to design and manufacture a micro-milling AMB spindle. The process involves a multidisciplinary design flow with a focus on critical practical aspects of manufacturing. The realized spindle is reported as a case study.

Automating garment assembly from sewing patterns remains a significant challenge due to the lack of standardized annotation protocols and the frequent absence of semantic cues. Existing methods often rely on panel labels or handcrafted heuristics, which limit their applicability to real-world, non-conforming patterns. We present AutoSew, a fully automatic, geometry-based approach for predicting stitch correspondences directly from 2D pattern contours. AutoSew formulates the problem as a graph matching task, leveraging a Graph Neural Network to capture local and global geometric context, and employing a differentiable optimal transport solver to infer stitching relationships-including multi-edge connections. To support this task, we update the GarmentCodeData dataset modifying over 18k patterns with realistic multi-edge annotations, reflecting industrial assembly scenarios. AutoSew achieves 96% F1-score and successfully assembles 73.3% of test garments without error, outperforming existing methods while relying solely on geometric input. Our results demonstrate that geometry alone can robustly guide stitching prediction, enabling scalable garment assembly without manual input.

Manufacturing automation in process planning, inspection planning, and digital-thread integration depends on a unified specification that binds the geometric features of a 3D CAD model to the geometric dimensioning and tolerancing (GD&T) callouts, datum definitions, and surface requirements carried by the corresponding 2D engineering drawing. Although Model-Based Definition (MBD) allows such specifications to be embedded directly in 3D models, 2D drawings remain the primary carrier of manufacturing intent in automotive, aerospace, shipbuilding, and heavy-machinery industries. Correctly linking drawing annotations to the corresponding 3D features is difficult because of contextual ambiguity, repeated feature patterns, and the need for transparent and traceable decisions. This paper presents a deterministic-first, context-aware framework that maps 2D drawing entities to 3D CAD features to produce a unified manufacturing specification. Drawing callouts are first semantically enriched and then scored against candidate features using an interpretable metric that combines type compatibility, tolerance-aware dimensional agreement, and conservative context consistency, along with engineering-domain heuristics. When deterministic scoring cannot resolve an ambiguity, the system escalates to multimodal and constrained large-language-model reasoning, followed by a single human-in-the-loop (HITL) review step. Experiments on 20 real CAD-drawing pairs achieve a mean precision of 83.67%, recall of 90.46%, and F1 score of 86.29%. An ablation study shows that each pipeline component contributes to overall accuracy, with the full system outperforming all reduced variants. By prioritizing deterministic rules, clear decision tracking, and retaining unresolved cases for human review, the framework provides a practical foundation for downstream manufacturing automation in real-world industrial environments.

Autonomous wire-harness assembly requires precise, reliable manipulation of branched cables, whose deformation is difficult to predict. Models for single Deformable Linear Objects (DLOs) do not extend directly to Branched DLOs (BDLOs), whose junctions couple bending, twisting, and stretching across branches. We introduce Differentiable discrete branched Elastic rods for modeling Furcated DLOs in real-Time (DEFT), a framework combining differentiable physics and learning for accurate BDLO dynamics, real-time inference, and dexterous manipulation planning. DEFT introduces momentum-conserving junction constraints to capture cross-branch coupling, supports mid-structure grasping, uses analytical gradients and branch-parallel computation for efficient parameter learning and inference, and incorporates a residual Graph Neural Network (GNN) to reduce long-horizon prediction errors. Experiments on six physical BDLOs with different topologies and materials demonstrate formulation-level generalization: the same formulation and residual-GNN architecture apply without redesign, with physical and learned parameters fitted separately for each BDLO. DEFT outperforms state-of-the-art physics-based and learning-based methods, achieving RMSEs of 0.93-2.14 cm over five-second recursive open-loop predictions and inference above 100 Hz. In real-world planning, DEFT achieves success rates of 36/40 for shape matching, 40/40 for parent-branch insertion, and 16/20 for child-branch insertion. These results demonstrate accurate, efficient, planning-compatible BDLO prediction for autonomous wire-harness manipulation. Project website: https://roahmlab.github.io/DEFT/.