Intelligent Vacuum Thermoforming Process

Ensuring consistent quality in vacuum thermoforming presents challenges due to variations in material properties and tooling configurations. This research introduces a vision-based quality control system to predict and optimise process parameters, thereby enhancing part quality with minimal data requirements. A comprehensive dataset was developed using visual data from vacuum-formed samples subjected to various process parameters, supplemented by image augmentation techniques to improve model training. A k-Nearest Neighbour algorithm was subsequently employed to identify adjustments needed in process parameters by mapping low-quality parts to their high-quality counterparts. The model exhibited strong performance in adjusting heating power, heating time, and vacuum time to reduce defects and improve production efficiency.

Hybrid Reasoning for Perception, Explanation, and Autonomous Action in Manufacturing

Industrial processes must be robust and adaptable, as environments and tasks are often unpredictable, while operational errors remain costly and difficult to detect. AI-based control systems offer a path forward, yet typically depend on supervised learning with extensive labelled datasets, which limits their ability to generalize across variable and data-scarce industrial settings. Foundation models could enable broader reasoning and knowledge integration, but rarely deliver the quantitative precision demanded by engineering applications. Here, we introduceControl and Interpretation of Production via Hybrid Expertise and Reasoning (CIPHER): a vision-language-action (VLA) model framework aiming to replicate human-like reasoning for industrial control, instantiated in a commercial-grade 3D printer. It integrates a process expert, a regression model enabling quantitative characterization of system states required for engineering tasks. CIPHER also incorporates retrieval-augmented generation to access external expert knowledge and support physics-informed, chain-of-thought reasoning. This hybrid architecture exhibits strong generalization to out-of-distribution tasks. It interprets visual or textual inputs from process monitoring, explains its decisions, and autonomously generates precise machine instructions, without requiring explicit annotations. CIPHER thus lays the foundations for autonomous systems that act with precision, reason with context, and communicate decisions transparently, supporting safe and trusted deployment in industrial settings.

Heterogeneous Image GNN: Graph-Conditioned Diffusion for Image Synthesis

We introduce a novel method for conditioning diffusion-based image synthesis models with heterogeneous graph data. Existing approaches typically incorporate conditioning variables directly into model architectures, either through cross-attention layers that attend to text latents or image concatenation that spatially restrict generation. However, these methods struggle to handle complex scenarios involving diverse, relational conditioning variables, which are more naturally represented as unstructured graphs. This paper presents Heterogeneous Image Graphs (HIG), a novel representation that models conditioning variables and target images as two interconnected graphs, enabling efficient handling of variable-length conditioning inputs and their relationships. We also propose a magnitude-preserving GNN that integrates the HIG into the existing EDM2 diffusion model using a ControlNet approach. Our approach improves upon the SOTA on a variety of conditioning inputs for the COCO-stuff and Visual Genome datasets, and showcases the ability to condition on graph attributes and relationships represented by edges in the HIG.

Regularized interpolation in 4D neural fields enables optimization of 3D printed geometries

The ability to accurately produce geometries with specified properties is perhaps the most important characteristic of a manufacturing process. 3D printing is marked by exceptional design freedom and complexity but is also prone to geometric and other defects that must be resolved for it to reach its full potential. Ultimately, this will require both astute design decisions and timely parameter adjustments to maintain stability that is challenging even with expert human operators. While machine learning is widely investigated in 3D printing, existing methods typically overlook spatial features that vary across prints and thus find it difficult to produce desired geometries. Here, we encode volumetric representations of printed parts into neural fields and apply a new regularization strategy, based on minimizing the partial derivative of the field's output with respect to a single, non-learnable parameter. By thus encouraging small input changes to yield only small output variations, we encourage smooth interpolation between observed volumes and hence realistic geometry predictions. This framework therefore allows the extraction of 'imagined' 3D shapes, revealing how a part would look if manufactured under previously unseen parameters. The resulting continuous field is used for data-driven optimization to maximize geometric fidelity between expected and produced geometries, reducing post-processing, material waste, and production costs. By optimizing process parameters dynamically, our approach enables advanced planning strategies, potentially allowing manufacturers to better realize complex and feature-rich designs.