Materials
Neural Co-Optimization of Structural Topology, Manufacturable Layers, and Path Orientations for Fiber-Reinforced Composites
Liu, Tao, Zhang, Tianyu, Chen, Yongxue, Wang, Weiming, Jiang, Yu, Huang, Yuming, Wang, Charlie C. L.
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.
Explainable AI for Correct Root Cause Analysis of Product Quality in Injection Moulding
Muaz, Muhammad, Sajid, Sameed, Schulze, Tobias, Liu, Chang, Klasen, Nils, Drescher, Benny
If a product deviates from its desired properties in the injection moulding process, its root cause analysis can be aided by models that relate the input machine settings with the output quality characteristics. The machine learning models tested in the quality prediction are mostly black boxes; therefore, no direct explanation of their prognosis is given, which restricts their applicability in the quality control. The previously attempted explainability methods are either restricted to tree-based algorithms only or do not emphasize on the fact that some explainability methods can lead to wrong root cause identification of a product's deviation from its desired properties. This study first shows that the interactions among the multiple input machine settings do exist in real experimental data collected as per a central composite design. Then, the model-agnostic explainable AI methods are compared for the first time to show that different explainability methods indeed lead to different feature impact analysis in injection moulding. Moreover, it is shown that the better feature attribution translates to the correct cause identification and actionable insights for the injection moulding process. Being model agnostic, explanations on both random forest and multilayer perceptron are performed for the cause analysis, as both models have the mean absolute percentage error of less than 0.05% on the experimental dataset.
Fabrication and Characterization of Additively Manufactured Stretchable Strain Sensors Towards the Shape Sensing of Continuum Robots
Moyer, Daniel C., Wang, Wenpeng, Karschner, Logan S., Fichera, Loris, Rao, Pratap M.
This letter describes the manufacturing and experimental characterization of novel stretchable strain sensors for continuum robots. The overarching goal of this research is to provide a new solution for the shape sensing of these devices. The sensors are fabricated via direct ink writing, an extrusion-based additive manufacturing technique. Electrically conductive material (i.e., the \textit{ink}) is printed into traces whose electrical resistance varies in response to mechanical deformation. The principle of operation of stretchable strain sensors is analogous to that of conventional strain gauges, but with a significantly larger operational window thanks to their ability to withstand larger strain. Among the different conductive materials considered for this study, we opted to fabricate the sensors with a high-viscosity eutectic Gallium-Indium ink, which in initial testing exhibited high linearity ($R^2 \approx$ 0.99), gauge factor $\approx$ 1, and negligible drift. Benefits of the proposed sensors include (i) ease of fabrication, as they can be conveniently printed in a matter of minutes; (ii) ease of installation, as they can simply be glued to the outside body of a robot; (iii) ease of miniaturization, which enables integration into millimiter-sized continuum robots.
Improving Physical Object State Representation in Text-to-Image Generative Systems
Chen, Tianle, Chakka, Chaitanya, Ghadiyaram, Deepti
Current text-to-image generative models struggle to accurately represent object states (e.g., "a table without a bottle," "an empty tumbler"). In this work, we first design a fully-automatic pipeline to generate high-quality synthetic data that accurately captures objects in varied states. Next, we fine-tune several open-source text-to-image models on this synthetic data. We evaluate the performance of the fine-tuned models by quantifying the alignment of the generated images to their prompts using GPT4o-mini, and achieve an average absolute improvement of 8+% across four models on the public GenAI-Bench dataset. We also curate a collection of 200 prompts with a specific focus on common objects in various physical states. We demonstrate a significant improvement of an average of 24+% over the baseline on this dataset. We release all evaluation prompts and code.
Conformal Prediction for Indoor Positioning with Correctness Coverage Guarantees
Zhou, Zhiyi, Peng, Hexin, Long, Hongyu
With the advancement of Internet of Things (IoT) technologies, high-precision indoor positioning has become essential for Location-Based Services (LBS) in complex indoor environments. Fingerprint-based localization is popular, but traditional algorithms and deep learning-based methods face challenges such as poor generalization, overfitting, and lack of interpretability. This paper applies conformal prediction (CP) to deep learning-based indoor positioning. CP transforms the uncertainty of the model into a non-conformity score, constructs prediction sets to ensure correctness coverage, and provides statistical guarantees. We also introduce conformal risk control for path navigation tasks to manage the false discovery rate (FDR) and the false negative rate (FNR).The model achieved an accuracy of approximately 100% on the training dataset and 85% on the testing dataset, effectively demonstrating its performance and generalization capability. Furthermore, we also develop a conformal p-value framework to control the proportion of position-error points. Experiments on the UJIIndoLoc dataset using lightweight models such as MobileNetV1, VGG19, MobileNetV2, ResNet50, and EfficientNet show that the conformal prediction technique can effectively approximate the target coverage, and different models have different performance in terms of prediction set size and uncertainty quantification.
Gaussian Process Regression for Active Sensing Probabilistic Structural Health Monitoring: Experimental Assessment Across Multiple Damage and Loading Scenarios
Amer, Ahmad, Kopsaftopoulos, Fotis
In the near future, Structural Health Monitoring (SHM) technologies will be capable of overcoming the drawbacks in the current maintenance and life-cycle management paradigms, namely: cost, increased downtime, less-than-optimal safety management paradigm and the limited applicability of fully-autonomous operations. In the context of SHM, one of the most challenging tasks is damage quantification. Current methods face accuracy and/or robustness issues when it comes to varying operating and environmental conditions. In addition, the damage/no-damage paradigm of current frameworks does not offer much information to maintainers on the ground for proper decision-making. In this study, a novel structural damage quantification framework is proposed based on widely-used Damage Indices (DIs) and Gaussian Process Regression Models (GPRMs). The novelty lies in calculating the probability of an incoming test DI point originating from a specific state, which allows for probability-educated decision-making. This framework is applied to three test cases: a Carbon Fiber-Reinforced Plastic (CFRP) coupon with attached weights as simulated damage, an aluminum coupon with a notch, and an aluminum coupon with attached weights as simulated damage under varying loading states. The state prediction method presented herein is applied to single-state quantification in the first two test cases, as well as the third one assuming the loading state is known. Finally, the proposed method is applied to the third test case assuming neither the damage size nor the load is known in order to predict both simultaneously from incoming DI test points. In applying this framework, two forms of GPRMs (standard and variational heteroscedastic) are used in order to critically assess their performances with respect to the three test cases.
When Star Wars becomes REALITY: Scientists reveal how you really could be frozen in 'carbonite' like Han Solo
In George Lucas's classic 1980 film'The Empire Strikes Back', hero Han Solo (Harrison Ford) is frozen in carbonite by the evil Darth Vader. The fictional metal hardened around the heroic space smuggler as it cooled – sealing him in a state of'perfect hibernation'. Carbonite is of course a fictional material, consigned to the realms of the Star Wars galaxy far, far away. But according to one scientist, this scene is not completely the stuff of science-fiction. Dr Alex Baker, a chemist at the University of Warwick, thinks humans could potentially be frozen like Solo with a real-life equivalent.
Transition States Energies from Machine Learning: An Application to Reverse Water-Gas Shift on Single-Atom Alloys
Cheula, Raffaele, Andersen, Mie
Obtaining accurate transition state (TS) energies is a bottleneck in computational screening of complex materials and reaction networks due to the high cost of TS search methods and first-principles methods such as density functional theory (DFT). Here we propose a machine learning (ML) model for predicting TS energies based on Gaussian process regression with the Wasserstein Weisfeiler-Lehman graph kernel (WWL-GPR). Applying the model to predict adsorption and TS energies for the reverse water-gas shift (RWGS) reaction on single-atom alloy (SAA) catalysts, we show that it can significantly improve the accuracy compared to traditional approaches based on scaling relations or ML models without a graph representation. Further benefitting from the low cost of model training, we train an ensemble of WWL-GPR models to obtain uncertainties through subsampling of the training data and show how these uncertainties propagate to turnover frequency (TOF) predictions through the construction of an ensemble of microkinetic models. Comparing the errors in model-based vs DFT-based TOF predictions, we show that the WWL-GPR model reduces errors by almost an order of magnitude compared to scaling relations. This demonstrates the critical impact of accurate energy predictions on catalytic activity estimation. Finally, we apply our model to screen new materials, identifying promising catalysts for RWGS. This work highlights the power of combining advanced ML techniques with DFT and microkinetic modeling for screening catalysts for complex reactions like RWGS, providing a robust framework for future catalyst design.
Triggering Hallucinations in LLMs: A Quantitative Study of Prompt-Induced Hallucination in Large Language Models
Hallucinations in large language models (LLMs) present a growing challenge across real-world applications, from healthcare to law, where factual reliability is essential. Despite advances in alignment and instruction tuning, LLMs can still generate outputs that are fluent yet fundamentally untrue. Understanding the cognitive dynamics that underlie these hallucinations remains an open problem. In this study, we propose a prompt-based framework to systematically trigger and quantify hallucination: a Hallucination-Inducing Prompt (HIP), which synthetically fuses semantically distant concepts (e.g., periodic table of elements and tarot divination) in a misleading way, and a Hallucination Quantifying Prompt (HQP), which scores the plausibility, confidence, and coherence of the output. Controlled experiments across multiple LLMs revealed that HIPs consistently produced less coherent and more hallucinated responses than their null-fusion controls. These effects varied across models, with reasoning-oriented LLMs showing distinct profiles from general-purpose ones. Our framework provides a reproducible testbed for studying hallucination vulnerability, and opens the door to developing safer, more introspective LLMs that can detect and self-regulate the onset of conceptual instability.