manufacturing engineers

Abstract: Several corrections of an executable model can fit the same observations while predicting different execution outcomes. We study a repair-to-execution interface that retains compatible finite guard repairs, conditions their weights on diagnostic and ordinary-execution observations, and uses their predictions to choose routes, priced tests, or a backup. On 24 synthetic two-stage devices, an equal mixture of a language-model-generated repair and a uniform belief over compatible repairs (the AI-weighted belief) lowers no-test cost by 2.14 percent relative to committing to the generated repair. Access charges can erase the benefit of diagnosis on isolated tasks, while repeated work can recover it under the AI-weighted belief. With normal-execution learning in every repeated-work arm, workload-valued testing costs 3.33 percent less than same-budget random selection under the AI-weighted belief. Weighting changes the comparison: uniform normal learning costs 540.75 less than AI-weighted normal learning on this cohort, with a device-paired interval excluding zero. Testing recovers part of that gap, but uniform normal learning still has a lower aggregate cost than AI-weighted workload-valued selection. Under uniform beliefs, information-gain selection has the lowest total among the compared selectors, while workload-valued testing costs more than normal learning. These results support retaining alternatives to a generated repair and evaluating diagnostic selection together with repair weighting and learning from execution.

Abstract: Existing methods for CAD reconstruction from 3D scans achieve strong performance on standard benchmarks, yet their effectiveness often degrades in real-world scenarios where objects consist of multiple parts and scan artifacts such as noise. A key reason is that current CAD reconstruction datasets predominantly contain single-part models and clean geometric inputs, limiting the ability of learned models to generalize to realistic settings. In this work, we introduce CADonatello, a part-aware framework for reconstructing parametric CAD models from real-world 3D scans. Our approach first decomposes the input geometry into structurally meaningful components using a foundation-scale 3D part segmentation model, and then reconstructs each component independently through a cross-section-driven pipeline that performs sketch parameterization followed by an extrusion. To improve the robustness of sketch parameterization to scan-derived cross-sections, we further introduce CC3D Cross-Sections, a dataset of paired rasterized cross-section images from realistic scans and their corresponding parametric sketches derived from aligned CAD models. This dataset enables effective domain adaptation from clean CAD sketch images to scan-derived cross-section images. Extensive experiments demonstrate that the proposed approach improves generalization to noisy scans and enables reliable reconstruction of complex multi-part objects across multiple real-world CAD reverse engineering benchmarks.

Abstract: Automated manufacturing requires data-driven decisions under uncertainty and sparse observational records, and unplanned downtime is a dominant cost of getting them wrong. Prescriptive maintenance recommends a maintenance action against an impending failure rather than merely predicting it. Established reference architectures couple predictive models with rule- or optimisation-based recommendation logic. Selecting a corrective action, however, requires an interventional quantity: how the line behaviour would change if the action were set. Manufacturing data is observational, so a model fitted to predict the outcome estimates an associational quantity and may misdirect the choice of action without the prediction error revealing it. Causal estimators target the interventional quantity but require an expert-led causal study per case, for which the bounded decision window of operation leaves no room. This dissertation analyses how causal reasoning can be embedded into prescriptive maintenance so that actions are ranked by their estimated interventional effect. The result is PriMa-Causa, built from three components: a causal reasoning layer that integrates the estimate into the PriMa reference model, a parametric simulator that supplies the interventional ground truth absent from manufacturing data, and a graph-conditioned tabular causal foundation model that, pre-trained once on this synthetic production-line prior, answers interventional queries in a single forward pass. PriMa-Causa attains a lower prescription error than associational baselines, with the largest margin under weak overlap and sparse context, and a partially disclosed causal graph reduces this error further. The causal inductive bias of the synthetic prior and the graph conditioning can thus replace per-case estimator fitting, a step toward automating causal inference for autonomous and self-healing maintenance.

Abstract: Decision support has become sophisticated at exploring uncertainty, but much less so at representing the architecture of the decision itself. As a result, the decision space is often narrowed before uncertainty is analyzed, leaving interactions among choices and the effects of alternatives they imply largely invisible. This paper introduces multichoice modeling, a framework for making large decision configuration spaces explicit and computationally explorable under uncertainty. Drawing on the logic of rugged landscapes, we conceptualize such problems as contingent performance landscapes, where interdependent choices generate configuration-specific outcomes whose value changes across uncertain futures. The computational framework combines multidimensional decision and uncertainty spaces in a single simulation. Further, variance-based sensitivity analysis is used for identifying influential choices, and conditional distribution analysis for comparing configuration-specific performance profiles. We demonstrate the framework through three case studies: a manufacturing process upgrade, M&A strategy, and mortgage design. By contrasting conventional uncertainty-only analysis with multichoice modeling, the cases show how opening the decision configuration space can reveal unexpected complementarities, near-best configurations with different risk profiles, and strategies that were not apparent as alternatives at the outset.

Abstract: Additive manufacturing, also known as 3D printing, is significant for its use in industries such as aerospace, robotics, medicine, and construction. However, digital mesh files remain vulnerable to geometry defects which can be introduced through malicious tampering or designer error. This can lead to hampered structural integrity and impede its use due to unexpected degradation of the part. To address these challenges, we propose SAMS, a multi-layered hierarchical graph framework designed to analyze meshes to enhance the Security of Additive Manufacturing Systems. SAMS captures geometric and topological information across mesh, facet, and surface levels, providing an adaptable architecture for targeted mesh processing tasks. We evaluate SAMS's accuracy against existing mesh processing tools. The graph construction results in rich structural representation and has the potential to significantly reduce downstream analytical complexity when detecting vulnerabilities. This paper presents SAMS, its formal graph-theoretic properties, and releases an open-source Python 3.12 implementation on GitHub (https://anonymous.4open.science/r/SAMS-graph-classes/) to facilitate future research in secure additive manufacturing systems software.

Abstract: Developing reliable predictive models for multi-physics systems often forces a compromise between computationally demanding physical simulators and data-hungry, opaque machine learning (ML) algorithms. While incorporating dimensional analysis into directed computation graphs offers a structurally sound alternative to explicitly solving partial differential equations (PDEs), such formulations typically yield underdetermined systems that act as imperfect simulators. We introduce pi-Net, a physics-informed latent variable model that resolves these imperfect simulators. The hybrid pi-Net architecture consists of an encoder that maps inputs into physically normalized latent space, which are then decoded into final predictions by a differentiable physics head. Evaluated on a real-world, data-scarce Gas Metal Arc Welding (GMAW) case study, the framework achieves an R2 of 0.864 with only 60 experimental samples. The results demonstrate that pi-Net significantly outperforms purely data-driven baselines in data-scarce regimes while providing causal, process-level explainability.

Abstract: Topology optimization has found significant utility in additive manufacturing, but the resulting geometries are often difficult to realize using subtractive methods. The complex, curved surfaces of optimized designs typically require time-consuming point milling operations. In contrast, geometries composed of developable surfaces are well suited to flank milling, enabling substantial improvements in machining efficiency and surface quality. However, globally minimizing Gaussian curvature leads to overly simplistic designs. We address this challenge with a novel method that represents geometry using three implicit neural fields, optimized to produce machinable components. The resulting designs consist of regions of developable surfaces separated by seamlines where curvature is concentrated. Seamlines are efficiently computed as intersections of the implicit fields, while the geometry emerges through their product. By constraining surfaces to align with the cutter's normal or tangential direction, our approach further accommodates practical constraints of 3-axis machining. We demonstrate concurrent optimization of topology and Gaussian curvature, enabling control over seamline feature scale. Compared to methods that enforce subtractive machinability without considering milling efficiency, our approach consistently reduces machining time while maintaining competitive structural performance.

Abstract: Turning a CAD design into an assembly plan is still largely done by hand, requiring engineers to reason about geometric feasibility, tool access, stability, and the ergonomics of human assembly. In this work, we encode long-established design for assembly (DfA) principles into a contained, end-to-end approach for generating assembly plans. Our approach takes only a mesh assembly and produces either a step-by-step assembly manual or a structured failure report, requiring no joint metadata, fastener annotations, or additional information. Four major components of a manufacturing plan are addressed autonomously: an assembly tool list, the assembly sequence and subassemblies, an assembly manual, and design feedback for improving assemblability. For determining the sequence plan, we systematically disassemble the object in a physics simulator and apply a cost function that encodes DfA principles. Manual generation, tool labelling, and assembly feedback rely primarily on multimodal large language models. Compared with a baseline that always removes the outermost part first from Tian et al., DfA-aware sequence planning reduces simulated assembly time, measured with a robot-arm assembly-time proxy, by 35% on 136 assemblies of 5 to 30 parts. The correct tool is selected for 88.6% of assembly steps. A vision-language model judge compares the generated manuals against ablated variants, identifying which page elements carry the information a reader needs. The presented approach and open-source code are available for use by engineers or AI agents looking to rapidly accelerate the creation of manufacturing plans for a given product design.

Abstract: A multi-domain eXtended Physics-Informed Neural Network (XPINN) framework is developed for nonsmooth Delay Differential Equations (DDEs). This is the first implementation to demonstrate the efficacy of partitioning the temporal domain into subdomains of integer multiples of the characteristic time delay and progressively training the associated subnetworks while freezing previously learned parameters. The efficacy of the proposed framework is demonstrated using a machining dynamics model that incorporates both regenerative and nonsmooth frictional effects. Results demonstrate that the proposed multi-domain XPINN framework leads to better solution reconstruction in DDEs and improved parameter estimation compared to a generic PINN (SPINN) formulation. The proposed method works particularly well for extended temporal domains and non-constant history functions. The robustness of inverse XPINN (I-XPINN) is also assessed using reference data contaminated with Gaussian measurement noise. Results indicate that I-XPINN remains resilient to measurement noise and the physics-informed constraints guide the network toward accurately recovering the underlying dynamics. This demonstrates, for the first time, the potential of the proposed framework for reliable parameter identification in DDEs characterised by nonsmoothness and large time delays.

Abstract: Learning to generate machining process plans and toolpaths from B-rep CAD requires coupling discrete operation decisions with continuous tool motion as the workpiece evolves. Correctly predicting an operation sequence does not by itself ensure correct material removal, because each toolpath acts on the stock left by preceding cuts. We formulate this problem around persistent manufacturing objects: object identity determines the target of an operation, while the evolving stock state conditions the generation of its toolpath. Based on this formulation, we propose CNCGEN, a dataset and learning framework for three-axis machining. CNCGEN-Dataset contains approximately 50k geometrically verified synthetic machining flows and 800 held-out real CNC records. Each flow aligns B-rep geometry with object-referenced operations, parameterized toolpaths, intermediate stock states, and verification outcomes, enabling supervision of the correspondence between planning decisions and their geometric effects. CNCGEN generates operations and toolpaths for selected objects step by step, updating a compact machining state to guide subsequent predictions. During training, a learned surrogate verifier provides material-removal feedback that links local predictions to their geometric consequences. Experiments on synthetic and held-out real CNC records show that CNCGEN improves the resulting workpiece geometry and reduces residual material and overcut compared with adapted CNC generation baselines.

Abstract: Counterfactual prediction estimates an individual's outcome under an alternative intervention given their factual observations. Such outcomes are generally not identifiable from observational data without additional assumptions. Even within the class of fully observed additive noise models (ANMs), different causal graphs can generate the same observational distribution yet imply different individual counterfactual outcomes. Predictions based on a single estimated graph ignore this structural uncertainty. We therefore target a Bayesian counterfactual posterior predictive distribution that combines predictions from plausible SCMs. We introduce CAFE (\textbf{C}ounterf\textbf{A}ctual Prediction via \textbf{F}ast Posterior \textbf{E}stimation), an amortized inference framework that directly approximates the Bayesian counterfactual posterior predictive distribution. We pretrain a transformer-based model on synthetic counterfactual tasks generated from a diverse prior over ANMs. Given an observational dataset, an individual's factual observations, and an intervention, CAFE approximates the corresponding posterior predictive distribution in a single forward pass. Experiments show that CAFE accurately predicts individual counterfactual outcomes in identifiable settings and approximates the posterior predictive distribution when structural uncertainty induced by observationally indistinguishable causal graphs exists. Strong performance in realistic manufacturing and viticulture settings further demonstrates its empirical robustness beyond the assumptions of the training prior.

Abstract: Automation systems must adapt to changing tasks, equipment states, and staffing conditions while providing evidence for human review. This study presents a multi-line task-adjustment system integrating a local large language model, a digital twin, and human decision-making. A Propose-Verify-Decide workflow translates operator intent into structured requirements, generates a bounded set of candidate strategies, and checks semantics, simulation execution, and operational constraints. Linked records preserve traceability from requests to verification evidence and decisions. Thirty fixed test records were evaluated using four virtual surgical-instrument sorting lines: 28 assessed the workflow and two assessed model generation. Eighteen workflow cases met expectations; autonomous strategy-workflow success was 3/10, and correct rejection of invalid inputs was 7/8. All four cases that passed preceding checks, produced complete evidence, and reached final engineering review (CP6) passed that review. Together with the correct blocking of strategies that failed throughput constraints, this supports the effectiveness of staged screening and confirmation within the tested setting. Mean placement-validation pass rate across eight simulation evidence records was 97.50%. Mean times to the first reviewable response and simulation verification, excluding startup, were 12.94 and 164.39 s, respectively. Remaining failures involved semantic distortion, incomplete evidence, and missed invalid inputs. The results demonstrate a traceable strategy-review workflow, but do not establish overall reliability or long-term stability. Broader testing and physical evaluation are needed to assess generalizability.

Abstract: Interlocking brick assembly provides a representative testbed for evaluating real-world robotic manipulation capabilities, where diverse structural designs, complex inter-step dependencies, intricate mechanical interactions and tight insertion tolerances pose substantial challenges. We present BrickCraft-Duo, a modular framework for long-horizon dual-arm collaborative assembly of interlocking bricks through data-efficient skill learning and composition. BrickCraft-Duo learns reusable single- and dual-arm assembly skills from diverse demonstrations, with bilateral symmetry alignment facilitating skill sharing across symmetric arms and assembly--support role assignments. Guided by stability-aware assembly reasoning, BrickCraft-Duo composes heterogeneous skills to achieve autonomous long-horizon execution, and further integrates human-in-the-loop correction for targeted skill refinement. The resulting system achieves long-horizon success rates of at least 60% and step-level completion rates of at least 95% across five real-world assembly tasks involving partially supported configurations, with horizons of up to nine steps. Project website: https://jichuan-yu.github.io/BrickCraft-Duo.

Abstract: The design of profile extrusion dies remains a challenging task due to the complex rheological behavior of polymer melts and the geometric intricacies of flow channels. Traditional manual optimization approaches, which rely heavily on human experience, are inefficient and often employ unvalidated heuristics. To address these challenges, we present a deterministic and explainable framework for automatic die design based on adjoint-based shape optimization. This approach enables the computation of sensitivities that directly indicate beneficial modifications to the flow channel geometry. A major difficulty in such optimization processes lies in generating boundary-conforming meshes that evolve consistently with changing geometries. To overcome this issue, we employ non-boundary conforming geometry representation methods that eliminate the need for an explicit surface representation along physical boundaries. A dedicated reconstruction technique is developed to recover accurate sensitivity information at the virtual interface between fluid and solid regions. The proposed algorithm is demonstrated on 3D geometries with varying complexity, including realistic extrusion die flow channels. Several objective functionals relevant to industrial applications, such as flow balance at the outflow, are considered. The results highlight significant improvements in performance metrics while maintaining numerical robustness. This work showcases the potential of adjoint-based techniques for automated die design in a domain still largely governed by manual trial-and-error procedures, establishing a foundation for data-efficient, sustainable manufacturing workflows using computational rheology.

Abstract: Robotic manipulation has increasingly pursued human-like dexterous hands with many articulated degrees of freedom, offering rich manipulation capabilities at the cost of mechanical and control complexity. At the other extreme, parallel grippers are simple and robust, but provide little ability to manipulate an object after grasping it. Operating articulated objects such as threaded containers, manufacturing tools, and laboratory instruments often requires a second gripper, an external fixture, or coordinated arm motion. We introduce the Cartesian Hand, a 7-DoF end-effector that rethinks dexterous manipulation by combining independent grasping and relative manipulation within a single end-effector using only linear motion. Two independently actuated parallel grippers hold different parts of an object, while four translating fingertips generate relative motion between the grasped parts. Its configuration-independent fingertip kinematics allow manipulation to be composed from simple linear motion primitives. The Cartesian Hand is particularly suited to objects structured around common mechanisms such as threads, pivots, linear guides, plungers, and triggers. We demonstrate cap opening and closing, pipetting, pumping, two-handle manipulation, screwdriving, trigger actuation, and in-grasp reorientation across 35 objects spanning laboratory, manufacturing, and household settings. The same manipulation procedures transfer from a fixed-base robot arm to a humanoid, where we demonstrate bimanual laboratory manipulation using two Cartesian Hands. These results show that versatile in-hand manipulation capability can emerge from a mechanically simple architecture when independent grasping and relative motion are designed directly into the end-effector. We will open-source all software and hardware design. Our website is https://generalroboticslab.com/cartesian_handv1.

Abstract: Causal Bayesian Optimization (CBO) combines causal inference with Bayesian optimization to enable sample-efficient intervention selection in systems with causal structure. This survey provides a systematic review of CBO through a unified BO-loop perspective, showing how causal assumptions shape intervention search spaces, surrogate models, acquisition functions, and decision policies. We organize existing methods by graph and system-knowledge assumptions, environment, intervention representation, surrogate architecture, and decision rule, and connect CBO to causal bandits, Bayesian experimental design, safe optimization, policy search, and causal abstraction. We also introduce a reproducibility-oriented benchmark spanning hard- and soft-intervention settings, with standardized GAP and a new trajectory-aware Path-Aware GAP (PA-GAP), evaluating seven CBO methods and a non-causal BO baseline across thirteen datasets, three budgets, and two metrics. Results show that no method dominates uniformly: rankings depend on dataset, budget, metric, and how causal information is used, while strong non-causal baselines remain competitive in several settings. Controlled graph-misspecification and omitted-variable stress tests further show that rankings can change substantially when learner-side causal information is perturbed. We conclude by identifying key open challenges, including robustness to causal-assumption violations, scalable unknown-graph optimization, mixed intervention types, realistic cost models, stronger theoretical guarantees, and integration with modern representation learning and causal abstractions.

Abstract: Manufacturing AI systems must autonomously adapt to continuous distributional shift from raw-material variability, ambient changes, and equipment aging, under strict safeguard and operator-trust requirements where model failures risk physical damage. This paper presents a closed-loop Cyber-Physical System (CPS) for autonomous model lifecycle management in automotive manufacturing, deployed since 2023. The system manages product-specialized model pairs: a sequence-to-sequence physics model (LPP) serving as a digital twin, and a deep Reinforcement Learning (RL) control policy (LCP) trained against it. Per retraining cycle, multiple model variants spanning architecture families and RL algorithms compete; only the best-scoring candidate advances. A Conductor orchestrator autonomously manages plant-wide model inventories with dependency-aware retraining and Proportional-Integral-Derivative (PID) fallback. Reflecting the principle of Human-Centric Intelligence, the LCP composite score embeds an operator-trust gate penalizing policies deviating from established practice; without it, 23% of policies are rejected by operators despite passing accuracy thresholds. Across multiple facilities, LCP-controlled processes achieve process stability improvements of 28-45% over uncontrolled baselines with zero safety incidents.

Abstract: High-mix low-volume (HMLV) manufacturing requires inspection systems to adapt to changing parts, specifications, and work orders without repeated task-specific programming. Existing inspection automation typically assumes predefined sensing sequences, while general purpose robot agents optimize task completion rather than the completeness and validity of metrological evidence. We formulate task-specified active metrological inspection and propose From Requirements to Admissible Metrological Evidence (FRAME), a hierarchical dual-arm framework that converts an inspection instruction and structured specification into traceable conformance evidence. FRAME coordinates learned manipulation with calibrated laser profilometry: a task manager grounds and schedules requirements, active surface correspondence verifies physical-to-specification localization, and evidence memory tracks measurement provenance, admissibility, and coverage. Learned components may propose inspection targets and physical access actions, but deterministic datum-grounded measurement, admissibility checks, coverage auditing, and conformance evaluation prevent incomplete or unverified evidence from authorizing PASS. A series of physical experiments shows that FRAME achieves higher end-to-end inspection reliability, fewer false accepts, and shorter task completion time.

Abstract: Magnetic levitation (MagLev) systems have great potential for application in high-mix, low-volume manufacturing due to their scalability and flexibility, enabling highly reconfigurable in-machine material flow. However, their manipulation capabilities remain largely unexploited, as current applications almost exclusively focus on transportation. To enable grasping and manipulation directly on MagLev systems without requiring additional costly handling equipment, such as industrial robot arms, we present the Gripper MagBot, a low-cost parallel 6-DoF manipulator with an integrated 1-DoF gripper that mechanically couples three MagLev movers. The Gripper MagBot supports two operating configurations: a default mode and a single-track mode, selectable depending on the required stability and workspace footprint. To reconfigure a machine, the MagBot can be autonomously dropped off and picked up using a docking station. We showcase pick-and-place examples in simulation, as well as with the real Gripper MagBot using our inverse kinematics controller. CAD files, assembly instructions, a component list, and videos are available at https://sites.google.com/view/gripper-magbot.

Abstract: This paper presents a novel approach for data-driven self-learning control of highly flexible, modular manufacturing systems. Specifically, we employ a novel framework for model-based reinforcement learning which introduces approximate inverse process models within the training of reinforcement policies. This approach disentangles the learning of actuation dynamics and the dynamics in state space, resulting in RL-based training solely within the task space. We propose a lightweight feedforward architecture for approximate inverse models and integrate them within the policy network of standard RL algorithms. We apply the approach to a laboratory modular production testbed with heterogeneous production modules. The results underline the efficiency improvements for modular manufacturing units in terms of both performance and training speed, particularly for off-policy algorithms.

Abstract: Boundary representation (B-rep) is the standard format used by modern CAD systems for parametric 3D models. It turns out, the exact same solid can be represented by different B-reps: for example, two engineers using different operations, a geometry kernel rebuilding the file, and an export setting repartitioning faces will lead to different B-reps even though the underlying solid remains the same. We show that existing B-rep encoders are not robust to variation in the B-rep with the same solid on perturbations applied to standard benchmarks, naturally occurring variations inherent to CAD software, and differences in how designers model the same part via a human dataset we created in FreeCAD. The performance of popular B-rep encoders often collapses catastrophically. We propose the canonical region graph, an input representation whose nodes, features and coordinate frame are derived from the solid itself and show theoretical invariance guarantees on repartitioning and rigid motions. It matches the strongest baseline on standard benchmarks, and is stable under every perturbation we test.

Abstract: Large language models (LLMs) have recently emerged as a promising tool for automating robot design from high-level specifications, yet they remain ineffective for robots operating under complex physical interactions. This limitation stems from the gap between language-based reasoning and the physical consequences of embodiment, often resulting in designs with low physical validity. In this work, we propose a multi-layered framework, AID-SR, that establishes a closed loop by translating simulator-observed physical states into structured feedback for the LLM designer. Combined with semantic critique, human feedback, and iterative refinement, the framework promotes the generation of physically feasible and functionally meaningful robot designs. We evaluate our approach on tendon-driven continuum robots across a benchmark of 14 tasks spanning reaching, grasping, locomotion, and manipulation. The proposed framework achieves 96.2% rate for passing the simulation feasibility check and by applying a common reinforcement learning training, 26.7% robots can successfully fulfill the corresponding task. We then fabricate three designed robots of AID-SR that successfully complete the task in real-world. These extensive experiments across simulation and real-world environments demonstrate and break the wall of utilizing the LLMs for automated design of continuum robots. The source code and experimental resources are publicly available at https://github.com/UNITES-Lab/AID-SR.

Abstract: Learning-by-Demonstration (LbD) enables intuitive robot programming by capturing expert skills, which is crucial for agility in high-mix, low- volume manufacturing. This systematic literature review analyzes passive LbD for industrial assembly processes, focusing on the perception architecture and the generalization of the perceived demonstration. We specifically investigate one-shot approaches where only a single demonstration is required. The review evaluates how systems adapt to new assemblies using this limited data. We identify a shift towards object-centric perception, allowing learned primitives to be transferred to new product variants with minimal training.