Daily Papers

Agentic systems enable the intelligent automation of complex workflows, specific to additive manufacturing this is applicable for complex tasks such as process parameter optimization for mechanical properties. This work investigates the AI enabled agentic process optimization within Selective Laser Sintering (SLS) to iteratively improve the tensile and flexural properties of 3 different materials on the Inova Mk1. These materials include PA12 GF, PA11 Onyx, and PA12 Blend (volume mixture of 25% PA12 GF and 75% PA12 White) and with using knowledge from previous builds and minimal guidance from the user, the agentic system was able to optimize process parameters over a small number of iterations to achieve comparable TDS specified mechanical properties. This work showcases the ability for an agentic system to continually learn from updated data, enabling the intelligent automation of complex tasks such as process parameter optimization for selective laser sintering.

An additive manufacturing (AM) process, like laser powder bed fusion, allows for the fabrication of objects by spreading and melting powder in layers until a freeform part shape is created. In order to improve the properties of the material involved in the AM process, it is important to predict the material characterization property as a function of the processing conditions. In thermoelectric materials, the power factor is a measure of how efficiently the material can convert heat to electricity. While earlier works have predicted the material characterization properties of different thermoelectric materials using various techniques, implementation of machine learning models to predict the power factor of bismuth telluride (Bi2Te3) during the AM process has not been explored. This is important as Bi2Te3 is a standard material for low temperature applications. Thus, we used data about manufacturing processing parameters involved and in-situ sensor monitoring data collected during AM of Bi2Te3, to train different machine learning models in order to predict its thermoelectric power factor. We implemented supervised machine learning techniques using 80% training and 20% test data and further used the permutation feature importance method to identify important processing parameters and in-situ sensor features which were best at predicting power factor of the material. Ensemble-based methods like random forest, AdaBoost classifier, and bagging classifier performed the best in predicting power factor with the highest accuracy of 90% achieved by the bagging classifier model. Additionally, we found the top 15 processing parameters and in-situ sensor features to characterize the material manufacturing property like power factor. These features could further be optimized to maximize power factor of the thermoelectric material and improve the quality of the products built using this material.

We present a deep learning approach for quantifying and localizing ex-situ porosity within Laser Powder Bed Fusion fabricated samples utilizing in-situ thermal image monitoring data. Our goal is to build the real time porosity map of parts based on thermal images acquired during the build. The quantification task builds upon the established Convolutional Neural Network model architecture to predict pore count and the localization task leverages the spatial and temporal attention mechanisms of the novel Video Vision Transformer model to indicate areas of expected porosity. Our model for porosity quantification achieved a R^2 score of 0.57 and our model for porosity localization produced an average IoU score of 0.32 and a maximum of 1.0. This work is setting the foundations of part porosity "Digital Twins" based on additive manufacturing monitoring data and can be applied downstream to reduce time-intensive post-inspection and testing activities during part qualification and certification. In addition, we seek to accelerate the acquisition of crucial insights normally only available through ex-situ part evaluation by means of machine learning analysis of in-situ process monitoring data.

Current analysis of additive manufactured niobium-based copper alloys relies on hand annotation due to varying contrast, noise, and image artifacts present in micrographs, slowing iteration speed in alloy development. We present a filtering and segmentation algorithm for detecting precipitates in FIB cross-section micrographs, optimized using linear genetic programming (LGP), which accounts for the various artifacts. To this end, the optimization environment uses a domain-specific language for image processing to iterate on solutions. Programs in this language are a list of image-filtering blocks with tunable parameters that sequentially process an input image, allowing for reliable generation and mutation by a genetic algorithm. Our environment produces optimized human-interpretable MATLAB code representing an image filtering pipeline. Under ideal conditions--a population size of 60 and a maximum program length of 5 blocks--our system was able to find a near-human accuracy solution with an average evaluation error of 1.8% when comparing segmentations pixel-by-pixel to a human baseline using an XOR error evaluation. Our automation work enabled faster iteration cycles and furthered exploration of the material composition and processing space: our optimized pipeline algorithm processes a 3.6 megapixel image in about 2 seconds on average. This ultimately enables convergence on strong, low-activation, precipitation hardened copper alloys for additive manufactured fusion reactor parts.

Addressing the uncertainty and variability in the quality of 3D printed metals can further the wide spread use of this technology. Process mapping for new alloys is crucial for determining optimal process parameters that consistently produce acceptable printing quality. Process mapping is typically performed by conventional methods and is used for the design of experiments and ex situ characterization of printed parts. On the other hand, in situ approaches are limited because their observable features are limited and they require complex high-cost setups to obtain temperature measurements to boost accuracy. Our method relaxes these limitations by incorporating the temporal features of molten metal dynamics during laser-metal interactions using video vision transformers and high-speed imaging. Our approach can be used in existing commercial machines and can provide in situ process maps for efficient defect and variability quantification. The generalizability of the approach is demonstrated by performing cross-dataset evaluations on alloys with different compositions and intrinsic thermofluid properties.

Laser cutting is a widely adopted technology in material processing across various industries, but it generates a significant amount of dust, smoke, and aerosols during operation, posing a risk to both the environment and workers' health. Speckle sensing has emerged as a promising method to monitor the cutting process and identify material types in real-time. This paper proposes a material classification technique using a speckle pattern of the material's surface based on deep learning to monitor and control the laser cutting process. The proposed method involves training a convolutional neural network (CNN) on a dataset of laser speckle patterns to recognize distinct material types for safe and efficient cutting. Previous methods for material classification using speckle sensing may face issues when the color of the laser used to produce the speckle pattern is changed. Experiments conducted in this study demonstrate that the proposed method achieves high accuracy in material classification, even when the laser color is changed. The model achieved an accuracy of 98.30 % on the training set and 96.88% on the validation set. Furthermore, the model was evaluated on a set of 3000 new images for 30 different materials, achieving an F1-score of 0.9643. The proposed method provides a robust and accurate solution for material-aware laser cutting using speckle sensing.

Insufficient overlap between the melt pools produced during Laser Powder Bed Fusion (L-PBF) can lead to lack-of-fusion defects and deteriorated mechanical and fatigue performance. In-situ monitoring of the melt pool subsurface morphology requires specialized equipment that may not be readily accessible or scalable. Therefore, we introduce a machine learning framework to correlate in-situ two-color thermal images observed via high-speed color imaging to the two-dimensional profile of the melt pool cross-section. Specifically, we employ a hybrid CNN-Transformer architecture to establish a correlation between single bead off-axis thermal image sequences and melt pool cross-section contours measured via optical microscopy. In this architecture, a ResNet model embeds the spatial information contained within the thermal images to a latent vector, while a Transformer model correlates the sequence of embedded vectors to extract temporal information. Our framework is able to model the curvature of the subsurface melt pool structure, with improved performance in high energy density regimes compared to analytical melt pool models. The performance of this model is evaluated through dimensional and geometric comparisons to the corresponding experimental melt pool observations.

Transformer-based Large Language Models (LLMs) have become a fixture in modern machine learning. Correspondingly, significant resources are allocated towards research that aims to further advance this technology, typically resulting in models of increasing size that are trained on increasing amounts of data. This work, however, demonstrates the surprising result that it is often possible to significantly improve the performance of LLMs by selectively removing higher-order components of their weight matrices. This simple intervention, which we call LAyer-SElective Rank reduction (LASER), can be done on a model after training has completed, and requires no additional parameters or data. We show extensive experiments demonstrating the generality of this finding across language models and datasets, and provide in-depth analyses offering insights into both when LASER is effective and the mechanism by which it operates.

Agentic systems enable the intelligent use of research tooling, augmenting a researcher's ability to investigate and propose novel solutions to existing problems. Within Additive Manufacturing (AM), alloy discovery remains a complex challenge, often requiring expertise in the various domains of materials science, thermodynamic simulations, and experimental analysis. Large Language Model (LLM) enabled agents can facilitate this endeavor by utilizing their extensive knowledge base to dispatch tool calls via Model Context Protocol (MCP) to perform actions such as Thermo-Calc property diagram calculations and lack of fusion process map generation. In addition, the multi-agent system developed in this work is able to effectively reason through complex user prompts and provide analysis on the printability of proposed alloys. These agents can dynamically adjust their task trajectory to the outcomes of tool call results, effectively enabling autonomous decision-making in practical environments. This work aims to utilize LLM enabled agents to automate and accelerate the task of alloy discovery within the field of additive manufacturing and showcase the benefits of adopting this multi-agent system.

Perovskite solar cells (PSCs) have rapidly emerged as a leading contender in next-generation photovoltaic technologies, owing to their exceptional power conversion efficiencies and advantageous material properties. Despite these advances, challenges such as long-term stability, environmental sustainability, and scalable manufacturing continue to hinder their commercialization. Precursor additive engineering has shown promise in addressing these issues by enhancing both the performance and durability of PSCs. However, the explosive growth of scientific literature and the complex interplay of materials, processes, and device architectures make it increasingly difficult for researchers to efficiently access, organize, and utilize domain knowledge in this rapidly evolving field. To address this gap, we introduce Perovskite-R1, a specialized large language model (LLM) with advanced reasoning capabilities tailored for the discovery and design of PSC precursor additives. By systematically mining and curating 1,232 high-quality scientific publications and integrating a comprehensive library of 33,269 candidate materials, we constructed a domain-specific instruction-tuning dataset using automated question-answer generation and chain-of-thought reasoning. Fine-tuning the QwQ-32B model on this dataset resulted in Perovskite-R1, which can intelligently synthesize literature insights and generate innovative and practical solutions for defect passivation and the selection of precursor additives. Experimental validation of several model-proposed strategies confirms their effectiveness in improving material stability and performance. Our work demonstrates the potential of domain-adapted LLMs in accelerating materials discovery and provides a closed-loop framework for intelligent, data-driven advancements in perovskite photovoltaic research.

Industry 4.0 has revolutionized manufacturing by driving digitalization and shifting the paradigm toward additive manufacturing (AM). Fused Deposition Modeling (FDM), a key AM technology, enables the creation of highly customized, cost-effective products with minimal material waste through layer-by-layer extrusion, posing a significant challenge to traditional subtractive methods. However, the susceptibility of material extrusion techniques to errors often requires expert intervention to detect and mitigate defects that can severely compromise product quality. While automated error detection and machine learning models exist, their generalizability across diverse 3D printer setups, firmware, and sensors is limited, and deep learning methods require extensive labeled datasets, hindering scalability and adaptability. To address these challenges, we present a process monitoring and control framework that leverages pre-trained Large Language Models (LLMs) alongside 3D printers to detect and address printing defects. The LLM evaluates print quality by analyzing images captured after each layer or print segment, identifying failure modes and querying the printer for relevant parameters. It then generates and executes a corrective action plan. We validated the effectiveness of the proposed framework in identifying defects by comparing it against a control group of engineers with diverse AM expertise. Our evaluation demonstrated that LLM-based agents not only accurately identify common 3D printing errors, such as inconsistent extrusion, stringing, warping, and layer adhesion, but also effectively determine the parameters causing these failures and autonomously correct them without any need for human intervention.

In this work we investigate the ability of large language models to predict additive manufacturing defect regimes given a set of process parameter inputs. For this task we utilize a process parameter defect dataset to fine-tune a collection of models, titled AdditiveLLM, for the purpose of predicting potential defect regimes including Keyholing, Lack of Fusion, and Balling. We compare different methods of input formatting in order to gauge the model's performance to correctly predict defect regimes on our sparse Baseline dataset and our natural language Prompt dataset. The model displays robust predictive capability, achieving an accuracy of 93\% when asked to provide the defect regimes associated with a set of process parameters. The incorporation of natural language input further simplifies the task of process parameters selection, enabling users to identify optimal settings specific to their build.

This research paper explores the impact of various input parameters, including Infill percentage, Layer Height, Extrusion Temperature, and Print Speed, on the resulting Tensile Strength in objects produced through additive manufacturing. The main objective of this study is to enhance our understanding of the correlation between the input parameters and Tensile Strength, as well as to identify the key factors influencing the performance of the additive manufacturing process. To achieve this objective, we introduced the utilization of Explainable Artificial Intelligence (XAI) techniques for the first time, which allowed us to analyze the data and gain valuable insights into the system's behavior. Specifically, we employed SHAP (SHapley Additive exPlanations), a widely adopted framework for interpreting machine learning model predictions, to provide explanations for the behavior of a machine learning model trained on the data. Our findings reveal that the Infill percentage and Extrusion Temperature have the most significant influence on Tensile Strength, while the impact of Layer Height and Print Speed is relatively minor. Furthermore, we discovered that the relationship between the input parameters and Tensile Strength is highly intricate and nonlinear, making it difficult to accurately describe using simple linear models.

This study explores cardiovascular stents fabricated using laser powder bed fusion (LPBF); an emerging method to offer patient-specific customisable parts. Here, the shape memory alloy NiTi, in a near equiatomic composition, was investigated to deconvolve the material response from macroscopic component effects. Specifically, stress-geometry interactions were revealed, in-situ, for a minaturised cardiovascular stent subjected to an externally applied cylindrical stress whilst acquiring synchrotron X-ray imaging and diffraction data. The approach enabled the collection of spatially resolved micromechanical deformation data; the formation of stress-induced martensite and R-phase was evident, occurring in locations near junctions between stent ligaments where stress concentrations exist. In the as-fabricated condition, hardness maps were obtained through nanoindentation, demonstrating that the localised deformation and deformation patterning is further controlled by porosity and microstructural heterogeneity. Electron backscatter diffraction (EBSD) supported these observations, showing a finer grain structure near stent junctions with higher associated lattice curvature. These features, combined with stress concentrations when loaded will initiate localised phase transformations. If the stent was subjected to repeated loading, representing in-vivo conditions, these regions would be susceptible to cyclic damage through transformation memory loss, leading to premature component failure. This study highlights the challenges that must be addressed for the post-processing treatment of LABF-processed stents for healthcare-related applications.

This paper presents a modeling effort to explore the underlying physics of temperature evolution during additive friction stir deposition (AFSD) by a human-AI teaming approach. AFSD is an emerging solid-state additive manufacturing technology that deposits materials without melting. However, both process modeling and modeling of the AFSD tool are at an early stage. In this paper, a human-AI teaming approach is proposed to combine models based on first principles with AI. The resulting human-informed machine learning method, denoted as AFSD-Physics, can effectively learn the governing equations of temperature evolution at the tool and the build from in-process measurements. Experiments are designed and conducted to collect in-process measurements for the deposition of aluminum 7075 with a total of 30 layers. The acquired governing equations are physically interpretable models with low computational cost and high accuracy. Model predictions show good agreement with the measurements. Experimental validation with new process parameters demonstrates the model's generalizability and potential for use in tool temperature control and process optimization.

In this paper, we propose the MultiLevel Variational MultiScale (ML-VMS) method, a novel approach that seamlessly integrates a multilevel mesh strategy into the Variational Multiscale (VMS) framework. A key feature of the ML-VMS method is the use of the Convolutional Hierarchical Deep Neural Network (C-HiDeNN) as the approximation basis. The framework employs a coarse mesh throughout the domain, with localized fine meshes placed only in subdomains of high interest, such as those surrounding a source. Solutions at different resolutions are robustly coupled through the variational weak form and interface conditions. Compared to existing multilevel methods, ML-VMS (1) can couple an arbitrary number of mesh levels across different scales using variational multiscale framework; (2) allows approximating functions with arbitrary orders with linear finite element mesh due to the C-HiDeNN basis; (3) is supported by a rigorous theoretical error analysis; (4) features several tunable hyperparameters (e.g., order p, patch size s) with a systematic guide for their selection. We first show the theoretical error estimates of ML-VMS. Then through numerical examples, we demonstrate that ML-VMS with the C-HiDeNN takes less computational time than the FEM basis given comparable accuracy. Furthermore, we incorporate a space-time reduced-order model (ROM) based on C-HiDeNN-Tensor Decomposition (TD) into the ML-VMS framework. For a large-scale single-track laser powder bed fusion (LPBF) transient heat transfer problem that is equivalent to a full-order finite element model with 10^{10} spatial degrees of freedom (DoFs), our 3-level ML-VMS C-HiDeNN-TD achieves an approximately 5,000x speedup on a single CPU over a single-level linear FEM-TD ROM.

The presence of strong electron clouds in the quadrupole magnetic field regions of the Large Hadron Collider (LHC) leads to considerable heating that poses challenges for the cryogenic cooling system, and under certain conditions to proton beam quality deterioration. Research is being conducted on laser-treated inner beam screen surfaces for the upgraded High-Luminosity LHC to mitigate this issue. Laser-induced surface structuring, a technique that effectively roughens surfaces, has been shown to reduce secondary electron emission; an essential factor in controlling electron cloud formation. Conversely, the resulting surface roughening also alters the material's surface impedance, potentially impacting beam stability and increasing beam-induced resistive wall heating. Different laser treatment patterns have been applied to LHC beam screens to estimate this potential impact and assessed for their microwave responses.

This work presents a collection of multi-modal domain adapted large language models built upon the instruction tuned variants of open weight models (Gemma 3, Qwen 3, Gemma 4) using a relatively small dataset of around 50 million tokens. The dataset consists of open-access additive manufacturing journal articles with data extracted for the domain adaptive pretraining and visual instruction tuning processes. Various stages of the developed model are evaluated with the Additive-Manufacturing-Benchmark which consists of additive manufacturing domain specific tasks compiled published resources. Domain adapted and instruction tuned models exhibit proficiency in both language and vision based tasks, achieving accuracies upwards of 90% in general additive manufacturing knowledge. This domain adaptive pretraining and instruction tuning strategy outline an accessible specialization method for large language models to a domain such as additive manufacturing.

The ability to generate 3D multiphase microstructures on-demand with targeted attributes can greatly accelerate the design of advanced materials. Here, we present a conditional latent diffusion model (LDM) framework that rapidly synthesizes high-fidelity 3D multiphase microstructures tailored to user specifications. Using this approach, we generate diverse two-phase and three-phase microstructures at high resolution (volumes of 128 times 128 times 64 voxels, representing >10^6 voxels each) within seconds, overcoming the scalability and time limitations of traditional simulation-based methods. Key design features, such as desired volume fractions and tortuosities, are incorporated as controllable inputs to guide the generative process, ensuring that the output structures meet prescribed statistical and topological targets. Moreover, the framework predicts corresponding manufacturing (processing) parameters for each generated microstructure, helping to bridge the gap between digital microstructure design and experimental fabrication. While demonstrated on organic photovoltaic (OPV) active-layer morphologies, the flexible architecture of our approach makes it readily adaptable to other material systems and microstructure datasets. By combining computational efficiency, adaptability, and experimental relevance, this framework addresses major limitations of existing methods and offers a powerful tool for accelerated materials discovery.

Mechanical design and manufacturing workflows conventionally begin with conceptual design, followed by the creation of a computer-aided design (CAD) model and fabrication through material-extrusion (MEX) printing. This process requires converting CAD geometry into machine-readable G-code through slicing and path planning. While each step is well established, dependence on CAD modeling remains a major bottleneck: constructing object-specific 3D geometry is slow and poorly suited to rapid prototyping. Even minor design variations typically necessitate manual updates in CAD software, making iteration time-consuming and difficult to scale. To address this limitation, we introduce Image2Gcode, an end-to-end data-driven framework that bypasses the CAD stage and generates printer-ready G-code directly from images and part drawings. Instead of relying on an explicit 3D model, a hand-drawn or captured 2D image serves as the sole input. The framework first extracts slice-wise structural cues from the image and then employs a denoising diffusion probabilistic model (DDPM) over G-code sequences. Through iterative denoising, the model transforms Gaussian noise into executable print-move trajectories with corresponding extrusion parameters, establishing a direct mapping from visual input to native toolpaths. By producing structured G-code directly from 2D imagery, Image2Gcode eliminates the need for CAD or STL intermediates, lowering the entry barrier for additive manufacturing and accelerating the design-to-fabrication cycle. This approach supports on-demand prototyping from simple sketches or visual references and integrates with upstream 2D-to-3D reconstruction modules to enable an automated pipeline from concept to physical artifact. The result is a flexible, computationally efficient framework that advances accessibility in design iteration, repair workflows, and distributed manufacturing.

With the rapid evolution of global autonomous driving technology, the demand for its core sensing hardware, Light Detection and Ranging (LiDAR), is escalating. As the light source part of the LiDAR system, lasers, particularly the cutting-edge Photonic Crystal Surface Emitting Lasers (PCSEL), have correspondingly attracted extensive research attention. The conventional manual design and optimization of PCSEL typically require expertise in semiconductor physics and months of dedicated effort to achieve satisfactory results. While AI-driven approaches can expedite this process, laser designers still need to invest time in learning the AI algorithms involved. Meanwhile Large Language Models (LLMs), leveraging their powerful reasoning abilities, can effectively comprehend natural language and provide constructive feedback in multi-turn dialogues. They have already demonstrated potential to assist humans in scientific fields such as robotics design and chemical discovery. A question naturally arises is: Can LLMs transform the lasers design process? This paper proposes a novel human-AI co-design paradigm to show that LLMs can guide the laser design and optimization process both conceptually and technically. Specifically, by simply having conversations, GPT assisted us with writing both Finite Difference Time Domain (FDTD) simulation code and deep reinforcement learning (RL) code to acquire the optimized PCSEL solution, spanning from the proposition of ideas to the realization of algorithms. Given that GPT will perform better when given detailed and specific prompts, we break down the PCSEL design problem into a series of sub-problems and converse with GPT by posing open-ended heuristic questions rather than definitive commands. We achieved a significant milestone towards self-driving laboratories, that is, a fully automated AI-driven pipeline, for laser design and production.