Product recalls provide valuable insights into potential risks and hazards within the engineering design process, yet their full potential remains underutilized. In this study, we curate data from the United States Consumer Product Safety Commission (CPSC) recalls database to develop a multimodal dataset, RECALL-MM, that informs data-driven risk assessment using historical information, and augment it using generative methods. Patterns in the dataset highlight specific areas where improved safety measures could have significant impact. We extend our analysis by demonstrating interactive clustering maps that embed all recalls into a shared latent space based on recall descriptions and product names. Leveraging these data-driven tools, we explore three case studies to demonstrate the dataset's utility in identifying product risks and guiding safer design decisions. The first two case studies illustrate how designers can visualize patterns across recalled products and situate new product ideas within the broader recall landscape to proactively anticipate hazards. In the third case study, we extend our approach by employing a large language model (LLM) to predict potential hazards based solely on product images. This demonstrates the model's ability to leverage visual context to identify risk factors, revealing strong alignment with historical recall data across many hazard categories. However, the analysis also highlights areas where hazard prediction remains challenging, underscoring the importance of risk awareness throughout the design process. Collectively, this work aims to bridge the gap between historical recall data and future product safety, presenting a scalable, data-driven approach to safer engineering design.

Deep neural networks are increasingly employed in fields such as climate modeling, robotics, and industrial control, where strict output constraints must be upheld. Although prior methods like the POLICE algorithm can enforce affine constraints in a single convex region by adjusting network parameters, they struggle with multiple disjoint regions, often leading to conflicts or unintended affine extensions. We present mPOLICE, a new method that extends POLICE to handle constraints imposed on multiple regions. mPOLICE assigns a distinct activation pattern to each constrained region, preserving exact affine behavior locally while avoiding overreach into other parts of the input domain. We formulate a layer-wise optimization problem that adjusts both the weights and biases to assign unique activation patterns to each convex region, ensuring that constraints are met without conflicts, while maintaining the continuity and smoothness of the learned function. Our experiments show the enforcement of multi-region constraints for multiple scenarios, including regression and classification, function approximation, and non-convex regions through approximation. Notably, mPOLICE adds zero inference overhead and minimal training overhead.

Deep generative models have recently shown success in solving complex engineering design problems where models predict solutions that address the design requirements specified as input. However, there remains a challenge in aligning such models for effective design exploration. For many design problems, finding a solution that meets all the requirements is infeasible. In such a case, engineers prefer to obtain a set of Pareto optimal solutions with respect to those requirements, but uniform sampling of generative models may not yield a useful Pareto front. To address this gap, we introduce a new framework for Pareto-front design exploration with simulation fine-tuned generative models. First, the framework adopts preference alignment methods developed for Large Language Models (LLMs) and showcases the first application in fine-tuning a generative model for engineering design. The important distinction here is that we use a simulator instead of humans to provide accurate and scalable feedback. Next, we propose epsilon-sampling, inspired by the epsilon-constraint method used for Pareto-front generation with classical optimization algorithms, to construct a high-quality Pareto front with the fine-tuned models. Our framework, named e-SimFT, is shown to produce better-quality Pareto fronts than existing multi-objective alignment methods.

Physical reasoning, which involves the interpretation, understanding, and prediction of object behavior in dynamic environments, remains a significant challenge for current Vision-Language Models (VLMs). In this work, we propose two methods to enhance VLMs' physical reasoning capabilities using simulated data. First, we fine-tune a pre-trained VLM using question-answer (QA) pairs generated from simulations relevant to physical reasoning tasks. Second, we introduce Physics Context Builders (PCBs), specialized VLMs fine-tuned to create scene descriptions enriched with physical properties and processes. During physical reasoning tasks, these PCBs can be leveraged as context to assist a Large Language Model (LLM) to improve its performance. We evaluate both of our approaches using multiple benchmarks, including a new stability detection QA dataset called Falling Tower, which includes both simulated and real-world scenes, and CLEVRER. We demonstrate that a small QA fine-tuned VLM can significantly outperform larger state-of-the-art foundational models. We also show that integrating PCBs boosts the performance of foundational LLMs on physical reasoning tasks. Using the real-world scenes from the Falling Tower dataset, we also validate the robustness of both approaches in Sim2Real transfer. Our results highlight the utility that simulated data can have in the creation of learning systems capable of advanced physical reasoning.

Requirements elicitation, a critical, yet time-consuming and challenging step in product development, often fails to capture the full spectrum of user needs. This may lead to products that fall short of expectations. This paper introduces a novel framework that leverages Large Language Models (LLMs) to automate and enhance the requirements elicitation process. LLMs are used to generate a vast array of simulated users (LLM agents), enabling the exploration of a much broader range of user needs and unforeseen use cases. These agents engage in product experience scenarios, through explaining their actions, observations, and challenges. Subsequent agent interviews and analysis uncover valuable user needs, including latent ones. We validate our framework with three experiments. First, we explore different methodologies for diverse agent generation, discussing their advantages and shortcomings. We measure the diversity of identified user needs and demonstrate that context-aware agent generation leads to greater diversity. Second, we show how our framework effectively mimics empathic lead user interviews, identifying a greater number of latent needs than conventional human interviews. Third, we showcase that LLMs can be used to analyze interviews, capture needs, and classify them as latent or not. Our work highlights the potential of using LLM agents to accelerate early-stage product development, reduce costs, and increase innovation.

The use of deep learning has become increasingly popular in reduced-order models (ROMs) to obtain low-dimensional representations of full-order models. Convolutional autoencoders (CAEs) are often used to this end as they are adept at handling data that are spatially distributed, including solutions to partial differential equations. When applied to unsteady physics problems, ROMs also require a model for time-series prediction of the low-dimensional latent variables. Long short-term memory (LSTM) networks, a type of recurrent neural network useful for modeling sequential data, are frequently employed in data-driven ROMs for autoregressive time-series prediction. When making predictions at unseen design points over long time horizons, error propagation is a frequently encountered issue, where errors made early on can compound over time and lead to large inaccuracies. In this work, we propose using bagging, a commonly used ensemble learning technique, to develop a fully data-driven ROM framework referred to as the CAE-eLSTM ROM that uses CAEs for spatial reconstruction of the full-order model and LSTM ensembles for time-series prediction. When applied to two unsteady fluid dynamics problems, our results show that the presented framework effectively reduces error propagation and leads to more accurate time-series prediction of latent variables at unseen points.

The lattice Boltzmann method (LBM) has emerged as a prominent technique for solving fluid dynamics problems due to its algorithmic potential for computational scalability. We introduce XLB library, a Python-based differentiable LBM library based on the JAX platform. The architecture of XLB is predicated upon ensuring accessibility, extensibility, and computational performance, enabling scaling effectively across CPU, TPU, multi-GPU, and distributed multi-GPU or TPU systems. The library can be readily augmented with novel boundary conditions, collision models, or multi-physics simulation capabilities. XLB's differentiability and data structure is compatible with the extensive JAX-based machine learning ecosystem, enabling it to address physics-based machine learning, optimization, and inverse problems. XLB has been successfully scaled to handle simulations with billions of cells, achieving giga-scale lattice updates per second. XLB is released under the permissive Apache-2.0 license and is available on GitHub at https://github.com/Autodesk/XLB.