A. John Hart

Aagam Shah, Reimar Weissbach, David A. Griggs et al.

With the increasing adoption of metal additive manufacturing (AM), researchers and practitioners are turning to data-driven approaches to optimise printing conditions. Cross-sectional images of melt tracks provide valuable information for tuning process parameters, developing parameter scaling data, and identifying defects. Here we present an image segmentation neural network that automatically identifies and measures melt track dimensions from a cross-section image. We use a U-Net architecture to train on a data set of 62 pre-labelled images obtained from different labs, machines, and materials coupled with image augmentation. When neural network hyperparameters such as batch size and learning rate are properly tuned, the learned model shows an accuracy for classification of over 99% and an F1 score over 90%. The neural network exhibits robustness when tested on images captured by various users, printed on different machines, and acquired using different microscopes. A post-processing module extracts the height and width of the melt pool, and the wetting angles. We discuss opportunities to improve model performance and avenues for transfer learning, such as extension to other AM processes such as directed energy deposition.

Kristen M. Edwards, Maxwell Bauer, Claire Jacquillat et al.

This work examines how AI, especially agentic systems, is being adopted in engineering and manufacturing workflows, what value it provides today, and what is needed for broader deployment. This is an exploratory and qualitative state-of-practice study grounded in over 30 interviews across four stakeholder groups (large enterprises, small/medium firms, AI developers, and CAD/CAM/CAE vendors). We find that near-term AI gains cluster around structured, repetitive work and data-intensive synthesis, while higher-value agentic gains come from orchestrating multi-step workflows across tools. Adoption is constrained less by model capability than by fragmented and machine-unfriendly data, stringent security and regulatory requirements, and limited API-accessible legacy toolchains. Reliability, verification, and auditability are central requirements for adoption, driving human-in-the-loop frameworks and governance aligned with existing engineering reviews. Beyond technical barriers there are also organizational ones: a persistent AI literacy gap, cultural heterogeneity, and governance structures that have not yet caught up with agentic capabilities. Together, the findings point to a staged progression of AI utility from low-consequence assistance toward higher-order automation, as trust, infrastructure, and verification mature. This highlights key breakthroughs needed, including integration with traditional engineering tools and data types, robust verification frameworks, and improved spatial and physical reasoning.

Nomi Yu, Md Ferdous Alam, A. John Hart et al.

CAD programs, structured as parametric sequences of commands that compile into precise 3D geometries, are fundamental to accurate and efficient engineering design processes. Generating these programs from nonparametric data such as point clouds and meshes remains a crucial yet challenging task, typically requiring extensive manual intervention. Current deep generative models aimed at automating CAD generation are significantly limited by imbalanced and insufficiently large datasets, particularly those lacking representation for complex CAD programs. To address this, we introduce GenCAD-3D, a multimodal generative framework utilizing contrastive learning for aligning latent embeddings between CAD and geometric encoders, combined with latent diffusion models for CAD sequence generation and retrieval. Additionally, we present SynthBal, a synthetic data augmentation strategy specifically designed to balance and expand datasets, notably enhancing representation of complex CAD geometries. Our experiments show that SynthBal significantly boosts reconstruction accuracy, reduces the generation of invalid CAD models, and markedly improves performance on high-complexity geometries, surpassing existing benchmarks. These advancements hold substantial implications for streamlining reverse engineering and enhancing automation in engineering design. We will publicly release our datasets and code, including a set of 51 3D-printed and laser-scanned parts on our project site.

Kylie Peppler, Joey Huang, Michael C. Richey et al.

Effective adoption of online platforms for teaching, learning, and skill development is essential to both academic institutions and workplaces. Adoption of online learning has been abruptly accelerated by COVID19 pandemic, drawing attention to research on pedagogy and practice for effective online instruction. Online learning requires a multitude of skills and resources spanning from learning management platforms to interactive assessment tools, combined with multimedia content, presenting challenges to instructors and organizations. This study focuses on ways that learning sciences and visual learning analytics can be used to design, and to improve, online workforce training in advanced manufacturing. Scholars and industry experts, educational researchers, and specialists in data analysis and visualization collaborated to study the performance of a cohort of 900 professionals enrolled in an online training course focused on additive manufacturing. The course was offered through MITxPro, MIT Open Learning is a professional learning organization which hosts in a dedicated instance of the edX platform. This study combines learning objective analysis and visual learning analytics to examine the relationships among learning trajectories, engagement, and performance. The results demonstrate how visual learning analytics was used for targeted course modification, and interpretation of learner engagement and performance, such as by more direct mapping of assessments to learning objectives, and to expected and actual time needed to complete each segment of the course. The study also emphasizes broader strategies for course designers and instructors to align course assignments, learning objectives, and assessment measures with learner needs and interests, and argues for a synchronized data infrastructure to facilitate effective just in time learning and continuous improvement of online courses.