We propose a neural network-based computational framework for the simultaneous optimization of structural topology, curved layers, and path orientations to achieve strong anisotropic strength in fiber-reinforced thermoplastic composites while ensuring manufacturability. Our framework employs three implicit neural fields to represent geometric shape, layer sequence, and fiber orientation. This enables the direct formulation of both design and manufacturability objectives - such as anisotropic strength, structural volume, machine motion control, layer curvature, and layer thickness - into an integrated and differentiable optimization process. By incorporating these objectives as loss functions, the framework ensures that the resultant composites exhibit optimized mechanical strength while remaining its manufacturability for filament-based multi-axis 3D printing across diverse hardware platforms. Physical experiments demonstrate that the composites generated by our co-optimization method can achieve an improvement of up to 33.1% in failure loads compared to composites with sequentially optimized structures and manufacturing sequences.

The deployment of machine learning (ML)-based process monitoring systems has significantly advanced additive manufacturing (AM) by enabling real-time defect detection, quality assessment, and process optimization. However, redundancy is a critical yet often overlooked challenge in the deployment and operation of ML-based AM process monitoring systems. Excessive redundancy leads to increased equipment costs, compromised model performance, and high computational requirements, posing barriers to industrial adoption. However, existing research lacks a unified definition of redundancy and a systematic framework for its evaluation and mitigation. This paper defines redundancy in ML-based AM process monitoring and categorizes it into sample-level, feature-level, and model-level redundancy. A comprehensive multi-level redundancy mitigation (MLRM) framework is proposed, incorporating advanced methods such as data registration, downscaling, cross-modality knowledge transfer, and model pruning to systematically reduce redundancy while improving model performance. The framework is validated through an ML-based in-situ defect detection case study for directed energy deposition (DED), demonstrating a 91% reduction in latency, a 47% decrease in error rate, and a 99.4% reduction in storage requirements. Additionally, the proposed approach lowers sensor costs and energy consumption, enabling a lightweight, cost-effective, and scalable monitoring system. By defining redundancy and introducing a structured mitigation framework, this study establishes redundancy analysis and mitigation as a key enabler of efficient ML-based process monitoring in production environments.

Despite significant interest and advancements in humanoid robotics, most existing commercially available hardware remains high-cost, closed-source, and non-transparent within the robotics community. This lack of accessibility and customization hinders the growth of the field and the broader development of humanoid technologies. To address these challenges and promote democratization in humanoid robotics, we demonstrate Berkeley Humanoid Lite, an open-source humanoid robot designed to be accessible, customizable, and beneficial for the entire community. The core of this design is a modular 3D-printed gearbox for the actuators and robot body. All components can be sourced from widely available e-commerce platforms and fabricated using standard desktop 3D printers, keeping the total hardware cost under $5,000 (based on U.S. market prices). The design emphasizes modularity and ease of fabrication. To address the inherent limitations of 3D-printed gearboxes, such as reduced strength and durability compared to metal alternatives, we adopted a cycloidal gear design, which provides an optimal form factor in this context. Extensive testing was conducted on the 3D-printed actuators to validate their durability and alleviate concerns about the reliability of plastic components. To demonstrate the capabilities of Berkeley Humanoid Lite, we conducted a series of experiments, including the development of a locomotion controller using reinforcement learning. These experiments successfully showcased zero-shot policy transfer from simulation to hardware, highlighting the platform's suitability for research validation. By fully open-sourcing the hardware design, embedded code, and training and deployment frameworks, we aim for Berkeley Humanoid Lite to serve as a pivotal step toward democratizing the development of humanoid robotics. All resources are available at https://lite.berkeley-humanoid.org.

Dexterous manipulation is a fundamental capability for robotic systems, yet progress has been limited by hardware trade-offs between precision, compactness, strength, and affordability. Existing control methods impose compromises on hand designs and applications. However, learning-based approaches present opportunities to rethink these trade-offs, particularly to address challenges with tendon-driven actuation and low-cost materials. This work presents RUKA, a tendon-driven humanoid hand that is compact, affordable, and capable. Made from 3D-printed parts and off-the-shelf components, RUKA has 5 fingers with 15 underactuated degrees of freedom enabling diverse human-like grasps. Its tendon-driven actuation allows powerful grasping in a compact, human-sized form factor. To address control challenges, we learn joint-to-actuator and fingertip-to-actuator models from motion-capture data collected by the MANUS glove, leveraging the hand's morphological accuracy. Extensive evaluations demonstrate RUKA's superior reachability, durability, and strength compared to other robotic hands. Teleoperation tasks further showcase RUKA's dexterous movements. The open-source design and assembly instructions of RUKA, code, and data are available at https://ruka-hand.github.io/.

-- Digital twins for power electronics require accurate power losses whose direct measurements are often impractical or impossible in real-world applications. This paper presents a novel hybrid framework that combines physics-based thermal modeling with data-driven techniques to identify and correct power losses accurately using only temperature measurements. Our approach leverages a cascaded architecture where a neural network learns to correct the outputs of a nominal power loss model by backpropagating through a reduced-order thermal model. We explore two neural architectures, a bootstrapped feedforward network, and a recurrent neural network, demonstrating that the bootstrapped feedforward approach achieves superior performance while maintaining computational efficiency for real-time applications. Between the interconnection, we included normalization strategies and physics-guided training loss functions to preserve stability and ensure physical consistency. Experimental results show that our hybrid model reduces both temperature estimation errors (from 7.2 6.8 C to 0.3 0.3 C) and power loss prediction errors (from 5.4 6.6W to 0.2 0.3W) compared to traditional physics-based approaches, even in the presence of thermal model uncertainties. This methodology allows us to accurately estimate power losses without direct measurements, making it particularly helpful for real-time industrial applications where sensor placement is hindered by cost and physical limitations. This paper has been accepted for presentation at the 23rd IEEE European Control Conference 2025 IEEE. Thermal management and sensing play a critical role in many industrial applications that rely on power electronics.

Additive Manufacturing (AM) is a promising solution for handling the complexity of fabricating soft robots. However, the AM of hyperelastic materials is still challenging with limited material types. Within this work, pellet-based 3D printing of very soft thermoplastic elastomers (TPEs) was explored. Our results show that TPEs can have similar engineering stress and maximum strain as Ecoflex OO-10. These TPEs were used to 3D-print airtight thin membranes (0.2-1.2 mm), which could inflate up to a stretch of 1320\%. Combining the membrane's large expansion and softness with the 3D printing of hollow structures simplified the design of a bending actuator that can bend 180 degrees and reach a blocked force of 238 times its weight. In addition, by 3D printing TPE pellets and rigid filaments, the soft membrane could grasp objects by enveloping an object or as a sensorized sucker, which relied on the TPE's softness to conform to the object or act as a seal. In addition, the membrane of the sucker was utilized as a tactile sensor to detect an object before adhesion. These results suggest the feasibility of 3D printing soft robots by using soft TPEs and membranes as an interesting class of materials and sensorized actuators, respectively.

Additive manufacturing (AM) has transformed the production landscape by enabling the precision creation of complex geometries. However, AM faces limitations when applied to challenging environments, such as elevated surfaces and remote locations. Aerial additive manufacturing, facilitated by drones, presents a solution to these challenges. However, despite advances in methods for the planning, control, and localization of drones, the accuracy of these methods is insufficient to run traditional feedforward extrusion-based additive manufacturing processes (such as Fused Deposition Manufacturing). Recently, the emergence of LLMs has revolutionized various fields by introducing advanced semantic reasoning and real-time planning capabilities. This paper proposes the integration of LLMs with aerial additive manufacturing to assist with the planning and execution of construction tasks, granting greater flexibility and enabling a feed-back based design and construction system. Using the semantic understanding and adaptability of LLMs, we can overcome the limitations of drone based systems by dynamically generating and adapting building plans on site, ensuring efficient and accurate construction even in constrained environments. Our system is able to design and build structures given only a semantic prompt and has shown success in understanding the spatial environment despite tight planning constraints. Our method's feedback system enables replanning using the LLM if the manufacturing process encounters unforeseen errors, without requiring complicated heuristics or evaluation functions. Combining the semantic planning with automatic error correction, our system achieved a 90% build accuracy, converting simple text prompts to build structures.

Efficient material logistics play a critical role in controlling costs and schedules in the construction industry. However, manual material handling remains prone to inefficiencies, delays, and safety risks. Autonomous forklifts offer a promising solution to streamline on-site logistics, reducing reliance on human operators and mitigating labor shortages. This paper presents the development and evaluation of the Autonomous Dynamic All-terrain Pallet Transporter (ADAPT), a fully autonomous off-road forklift designed for construction environments. Unlike structured warehouse settings, construction sites pose significant challenges, including dynamic obstacles, unstructured terrain, and varying weather conditions. To address these challenges, our system integrates AI-driven perception techniques with traditional approaches for decision making, planning, and control, enabling reliable operation in complex environments. We validate the system through extensive real-world testing, comparing its long-term performance against an experienced human operator across various weather conditions. We also provide a comprehensive analysis of challenges and key lessons learned, contributing to the advancement of autonomous heavy machinery. Our findings demonstrate that autonomous outdoor forklifts can operate near human-level performance, offering a viable path toward safer and more efficient construction logistics.

This paper introduces a chain-driven, sandwich-legged, mid-size quadruped robot designed as an accessible research platform. The design prioritizes enhanced locomotion capabilities, improved reliability and safety of the actuation system, and simplified, cost-effective manufacturing processes. Locomotion performance is optimized through a sandwiched leg design and a dual-motor configuration, reducing leg inertia for agile movements. Reliability and safety are achieved by integrating robust cable strain reliefs, efficient heat sinks for motor thermal management, and mechanical limits to restrict leg motion. Simplified design considerations include a quasi-direct drive (QDD) actuator and the adoption of low-cost fabrication techniques, such as laser cutting and 3D printing, to minimize cost and ensure rapid prototyping. The robot weighs approximately 25 kg and is developed at a cost under \$8000, making it a scalable and affordable solution for robotics research. Experimental validations demonstrate the platform's capability to execute trot and crawl gaits on flat terrain and slopes, highlighting its potential as a versatile and reliable quadruped research platform.

With the advancement of Industry 4.0, intelligent manufacturing extensively employs sensors for real-time multidimensional data collection, playing a crucial role in equipment monitoring, process optimisation, and efficiency enhancement. Industrial data exhibit characteristics such as multi-source heterogeneity, nonlinearity, strong coupling, and temporal interactions, while also being affected by noise interference. These complexities make it challenging for traditional anomaly detection methods to extract key features, impacting detection accuracy and stability. Traditional machine learning approaches often struggle with such complex data due to limitations in processing capacity and generalisation ability, making them inadequate for practical applications. While deep learning feature extraction modules have demonstrated remarkable performance in image and text processing, they remain ineffective when applied to multi-source heterogeneous industrial data lacking explicit correlations. Moreover, existing multi-source heterogeneous data processing techniques still rely on dimensionality reduction and feature selection, which can lead to information loss and difficulty in capturing high-order interactions. To address these challenges, this study applies the EAPCR and Time-EAPCR models proposed in previous research and introduces a new model, Time-EAPCR-T, where Transformer replaces the LSTM module in the time-series processing component of Time-EAPCR. This modification effectively addresses multi-source data heterogeneity, facilitates efficient multi-source feature fusion, and enhances the temporal feature extraction capabilities of multi-source industrial data.Experimental results demonstrate that the proposed method outperforms existing approaches across four industrial datasets, highlighting its broad application potential.