Capturing Local Temperature Evolution during Additive Manufacturing through Fourier Neural Operators

High-fidelity, data-driven models that can quickly simulate thermal behavior during additive manufacturing (AM) are crucial for improving the performance of AM technologies in multiple areas, such as part design, process planning, monitoring, and control. However, the complexities of part geometries make it challenging for current models to maintain high accuracy across a wide range of geometries. Additionally, many models report a low mean square error (MSE) across the entire domain (part). However, in each time step, most areas of the domain do not experience significant changes in temperature, except for the heat-affected zones near recent depositions. Therefore, the MSE-based fidelity measurement of the models may be overestimated. This paper presents a data-driven model that uses Fourier Neural Operator to capture the local temperature evolution during the additive manufacturing process. In addition, the authors propose to evaluate the model using the $R^2$ metric, which provides a relative measure of the model's performance compared to using mean temperature as a prediction. The model was tested on numerical simulations based on the Discontinuous Galerkin Finite Element Method for the Direct Energy Deposition process, and the results demonstrate that the model achieves high fidelity as measured by $R^2$ and maintains generalizability to geometries that were not included in the training process.

Smoothing the Rough Edges: Evaluating Automatically Generated Multi-Lattice Transitions

Additive manufacturing is advantageous for producing lightweight components while addressing complex design requirements. This capability has been bolstered by the introduction of unit lattice cells and the gradation of those cells. In cases where loading varies throughout a part, it may be beneficial to use multiple, distinct lattice cell types, resulting in multi-lattice structures. In such structures, abrupt transitions between unit cell topologies may cause stress concentrations, making the boundary between unit cell types a primary failure point. Thus, these regions require careful design in order to ensure the overall functionality of the part. Although computational design approaches have been proposed, smooth transition regions are still difficult to achieve, especially between lattices of drastically different topologies. This work demonstrates and assesses a method for using variational autoencoders to automate the creation of transitional lattice cells, examining the factors that contribute to smooth transitions. Through computational experimentation, it was found that the smoothness of transition regions was strongly predicted by how closely the endpoints were in the latent space, whereas the number of transition intervals was not a sole predictor.

AircraftVerse: A Large-Scale Multimodal Dataset of Aerial Vehicle Designs

We present AircraftVerse, a publicly available aerial vehicle design dataset. Aircraft design encompasses different physics domains and, hence, multiple modalities of representation. The evaluation of these cyber-physical system (CPS) designs requires the use of scientific analytical and simulation models ranging from computer-aided design tools for structural and manufacturing analysis, computational fluid dynamics tools for drag and lift computation, battery models for energy estimation, and simulation models for flight control and dynamics. AircraftVerse contains 27,714 diverse air vehicle designs - the largest corpus of engineering designs with this level of complexity. Each design comprises the following artifacts: a symbolic design tree describing topology, propulsion subsystem, battery subsystem, and other design details; a STandard for the Exchange of Product (STEP) model data; a 3D CAD design using a stereolithography (STL) file format; a 3D point cloud for the shape of the design; and evaluation results from high fidelity state-of-the-art physics models that characterize performance metrics such as maximum flight distance and hover-time. We also present baseline surrogate models that use different modalities of design representation to predict design performance metrics, which we provide as part of our dataset release. Finally, we discuss the potential impact of this dataset on the use of learning in aircraft design and, more generally, in CPS. AircraftVerse is accompanied by a data card, and it is released under Creative Commons Attribution-ShareAlike (CC BY-SA) license. The dataset is hosted at https://zenodo.org/record/6525446, baseline models and code at https://github.com/SRI-CSL/AircraftVerse, and the dataset description at https://aircraftverse.onrender.com/.

Conceptual Design Generation Using Large Language Models

Concept generation is a creative step in the conceptual design phase, where designers often turn to brainstorming, mindmapping, or crowdsourcing design ideas to complement their own knowledge of the domain. Recent advances in natural language processing (NLP) and machine learning (ML) have led to the rise of Large Language Models (LLMs) capable of generating seemingly creative outputs from textual prompts. The success of these models has led to their integration and application across a variety of domains, including art, entertainment, and other creative work. In this paper, we leverage LLMs to generate solutions for a set of 12 design problems and compare them to a baseline of crowdsourced solutions. We evaluate the differences between generated and crowdsourced design solutions through multiple perspectives, including human expert evaluations and computational metrics. Expert evaluations indicate that the LLM-generated solutions have higher average feasibility and usefulness while the crowdsourced solutions have more novelty. We experiment with prompt engineering and find that leveraging few-shot learning can lead to the generation of solutions that are more similar to the crowdsourced solutions. These findings provide insight into the quality of design solutions generated with LLMs and begins to evaluate prompt engineering techniques that could be leveraged by practitioners to generate higher-quality design solutions synergistically with LLMs.

Learning to design without prior data: Discovering generalizable design strategies using deep learning and tree search

Building an AI agent that can design on its own has been a goal since the 1980s. Recently, deep learning has shown the ability to learn from large-scale data, enabling significant advances in data-driven design. However, learning over prior data limits us only to solve problems that have been solved before and biases data-driven learning towards existing solutions. The ultimate goal for a design agent is the ability to learn generalizable design behavior in a problem space without having seen it before. We introduce a self-learning agent framework in this work that achieves this goal. This framework integrates a deep policy network with a novel tree search algorithm, where the tree search explores the problem space, and the deep policy network leverages self-generated experience to guide the search further. This framework first demonstrates an ability to discover high-performing generative strategies without any prior data, and second, it illustrates a zero-shot generalization of generative strategies across various unseen boundary conditions. This work evaluates the effectiveness and versatility of the framework by solving multiple versions of two engineering design problems without retraining. Overall, this paper presents a methodology to self-learn high-performing and generalizable problem-solving behavior in an arbitrary problem space, circumventing the needs for expert data, existing solutions, and problem-specific learning.

Design Strategy Network: A deep hierarchical framework to represent generative design strategies in complex action spaces

Generative design problems often encompass complex action spaces that may be divergent over time, contain state-dependent constraints, or involve hybrid (discrete and continuous) domains. To address those challenges, this work introduces Design Strategy Network (DSN), a data-driven deep hierarchical framework that can learn strategies over these arbitrary complex action spaces. The hierarchical architecture decomposes every action decision into first predicting a preferred spatial region in the design space and then outputting a probability distribution over a set of possible actions from that region. This framework comprises a convolutional encoder to work with image-based design state representations, a multi-layer perceptron to predict a spatial region, and a weight-sharing network to generate a probability distribution over unordered set-based inputs of feasible actions. Applied to a truss design study, the framework learns to predict the actions of human designers in the study, capturing their truss generation strategies in the process. Results show that DSNs significantly outperform non-hierarchical methods of policy representation, demonstrating their superiority in complex action space problems.

Goal-Directed Design Agents: Integrating Visual Imitation with One-Step Lookahead Optimization for Generative Design

Engineering design problems often involve large state and action spaces along with highly sparse rewards. Since an exhaustive search of those spaces is not feasible, humans utilize relevant domain knowledge to condense the search space. Previously, deep learning agents (DLAgents) were introduced to use visual imitation learning to model design domain knowledge. This note builds on DLAgents and integrates them with one-step lookahead search to develop goal-directed agents capable of enhancing learned strategies for sequentially generating designs. Goal-directed DLAgents can employ human strategies learned from data along with optimizing an objective function. The visual imitation network from DLAgents is composed of a convolutional encoder-decoder network, acting as a rough planning step that is agnostic to feedback. Meanwhile, the lookahead search identifies the fine-tuned design action guided by an objective. These design agents are trained on an unconstrained truss design problem that is modeled as a sequential, action-based configuration design problem. The agents are then evaluated on two versions of the problem: the original version used for training and an unseen constrained version with an obstructed construction space. The goal-directed agents outperform the human designers used to train the network as well as the previous objective-agnostic versions of the agent in both scenarios. This illustrates a design agent framework that can efficiently use feedback to not only enhance learned design strategies but also adapt to unseen design problems.

Learning to design from humans: Imitating human designers through deep learning

Humans as designers have quite versatile problem-solving strategies. Computer agents on the other hand can access large scale computational resources to solve certain design problems. Hence, if agents can learn from human behavior, a synergetic human-agent problem solving team can be created. This paper presents an approach to extract human design strategies and implicit rules, purely from historical human data, and use that for design generation. A two-step framework that learns to imitate human design strategies from observation is proposed and implemented. This framework makes use of deep learning constructs to learn to generate designs without any explicit information about objective and performance metrics. The framework is designed to interact with the problem through a visual interface as humans did when solving the problem. It is trained to imitate a set of human designers by observing their design state sequences without inducing problem-specific modelling bias or extra information about the problem. Furthermore, an end-to-end agent is developed that uses this deep learning framework as its core in conjunction with image processing to map pixel-to-design moves as a mechanism to generate designs. Finally, the designs generated by a computational team of these agents are then compared to actual human data for teams solving a truss design problem. Results demonstrates that these agents are able to create feasible and efficient truss designs without guidance, showing that this methodology allows agents to learn effective design strategies.