Efficient Semi-Automated Material Microstructure Analysis Using Deep Learning: A Case Study in Additive Manufacturing

Image segmentation is fundamental to microstructural analysis for defect identification and structure-property correlation, yet remains challenging due to pronounced heterogeneity in materials images arising from varied processing and testing conditions. Conventional image processing techniques often fail to capture such complex features rendering them ineffective for large-scale analysis. Even deep learning approaches struggle to generalize across heterogeneous datasets due to scarcity of high-quality labeled data. Consequently, segmentation workflows often rely on manual expert-driven annotations which are labor intensive and difficult to scale. Using an additive manufacturing (AM) dataset as a case study, we present a semi-automated active learning based segmentation pipeline that integrates a U-Net based convolutional neural network with an interactive user annotation and correction interface and a representative core-set image selection strategy. The active learning workflow iteratively updates the model by incorporating user corrected segmentations into the training pool while the core-set strategy identifies representative images for annotation. Three subset selection strategies, manual selection, uncertainty driven sampling and proposed maximin Latin hypercube sampling from embeddings (SMILE) method were evaluated over six refinement rounds. The SMILE strategy consistently outperformed other approaches, improving the macro F1 score from 0.74 to 0.93 while reducing manual annotation time by about 65 percent. The segmented defect regions were further analyzed using a coupled classification model to categorize defects based on microstructural characteristics and map them to corresponding AM process parameters. The proposed framework reduces labeling effort while maintaining scalability and robustness and is broadly applicable to image based analysis across diverse materials systems.

Sustainable Materials Discovery in the Era of Artificial Intelligence

Artificial intelligence (AI) has transformed materials discovery, enabling rapid exploration of chemical space through generative models and surrogate screening. Yet current AI workflows optimize performance first, deferring sustainability to post synthesis assessment. This creates inefficiency by the time environmental burdens are quantified, resources have been invested in potentially unsustainable solutions. The disconnect between atomic scale design and lifecycle assessment (LCA) reflects fundamental challenges, data scarcity across heterogeneous sources, scale gaps from atoms to industrial systems, uncertainty in synthesis pathways, and the absence of frameworks that co-optimize performance with environmental impact. We propose to integrate upstream machine learning (ML) assisted materials discovery with downstream lifecycle assessment into a uniform ML-LCA environment. The framework ML-LCA integrates five components, information extraction for building materials-environment knowledge bases, harmonized databases linking properties to sustainability metrics, multi-scale models bridging atomic properties to lifecycle impacts, ensemble prediction of manufacturing pathways with uncertainty quantification, and uncertainty-aware optimization enabling simultaneous performance-sustainability navigation. Case studies spanning glass, cement, semiconductor photoresists, and polymers demonstrate both necessity and feasibility while identifying material-specific integration challenges. Realizing ML-LCA demands coordinated advances in data infrastructure, ex-ante assessment methodologies, multi-objective optimization, and regulatory alignment enabling the discovery of materials that are sustainable by design rather than by chance.

Enhancing Experimental Efficiency in Materials Design: A Comparative Study of Taguchi and Machine Learning Methods

Materials design problems often require optimizing multiple variables, rendering full factorial exploration impractical. Design of experiment (DOE) methods, such as Taguchi technique, are commonly used to efficiently sample the design space but they inherently lack the ability to capture non-linear dependency of process variables. In this work, we demonstrate how machine learning (ML) methods can be used to overcome these limitations. We compare the performance of Taguchi method against an active learning based Gaussian process regression (GPR) model in a wire arc additive manufacturing (WAAM) process to accurately predict aspects of bead geometry, including penetration depth, bead width, and height. While Taguchi method utilized a three-factor, five-level L25 orthogonal array to suggest weld parameters, the GPR model used an uncertainty-based exploration acquisition function coupled with latin hypercube sampling for initial training data. Accuracy and efficiency of both models was evaluated on 15 test cases, with GPR outperforming Taguchi in both metrics. This work applies to broader materials processing domain requiring efficient exploration of complex parameters.

Polymers for Extreme Conditions Designed Using Syntax-Directed Variational Autoencoders

The design/discovery of new materials is highly non-trivial owing to the near-infinite possibilities of material candidates, and multiple required property/performance objectives. Thus, machine learning tools are now commonly employed to virtually screen material candidates with desired properties by learning a theoretical mapping from material-to-property space, referred to as the \emph{forward} problem. However, this approach is inefficient, and severely constrained by the candidates that human imagination can conceive. Thus, in this work on polymers, we tackle the materials discovery challenge by solving the \emph{inverse} problem: directly generating candidates that satisfy desired property/performance objectives. We utilize syntax-directed variational autoencoders (VAE) in tandem with Gaussian process regression (GPR) models to discover polymers expected to be robust under three extreme conditions: (1) high temperatures, (2) high electric field, and (3) high temperature \emph{and} high electric field, useful for critical structural, electrical and energy storage applications. This approach to learn from (and augment) human ingenuity is general, and can be extended to discover polymers with other targeted properties and performance measures.

Polymer Informatics: Current Status and Critical Next Steps

Artificial intelligence (AI) based approaches are beginning to impact several domains of human life, science and technology. Polymer informatics is one such domain where AI and machine learning (ML) tools are being used in the efficient development, design and discovery of polymers. Surrogate models are trained on available polymer data for instant property prediction, allowing screening of promising polymer candidates with specific target property requirements. Questions regarding synthesizability, and potential (retro)synthesis steps to create a target polymer, are being explored using statistical means. Data-driven strategies to tackle unique challenges resulting from the extraordinary chemical and physical diversity of polymers at small and large scales are being explored. Other major hurdles for polymer informatics are the lack of widespread availability of curated and organized data, and approaches to create machine-readable representations that capture not just the structure of complex polymeric situations but also synthesis and processing conditions. Methods to solve inverse problems, wherein polymer recommendations are made using advanced AI algorithms that meet application targets, are being investigated. As various parts of the burgeoning polymer informatics ecosystem mature and become integrated, efficiency improvements, accelerated discoveries and increased productivity can result. Here, we review emergent components of this polymer informatics ecosystem and discuss imminent challenges and opportunities.