A. John Hart

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.

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.

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.

Aanish Paruchuri, Carl Thrasher, A. J. Hart et al.

Nanoparticle superlattices consisting of ordered arrangements of nanoparticles exhibit unique optical, magnetic, and electronic properties arising from nanoparticle characteristics as well as their collective behaviors. Understanding how processing conditions influence the nanoscale arrangement and microstructure is critical for engineering materials with desired macroscopic properties. Microstructural features such as grain boundaries, lattice defects, and pores significantly affect these properties but are challenging to quantify using traditional manual analyses as they are labor-intensive and prone to errors. In this work, we present a machine learning workflow for automating grain segmentation in scanning electron microscopy (SEM) images of nanoparticle superlattices. This workflow integrates signal processing techniques, such as Radon transforms, with unsupervised learning methods like agglomerative hierarchical clustering to identify and segment grains without requiring manually annotated data. In the workflow we transform the raw pixel data into explainable numerical representation of superlattice orientations for clustering. Benchmarking results demonstrate the workflow's robustness against noisy images and edge cases, with a processing speed of four images per minute on standard computational hardware. This efficiency makes the workflow scalable to large datasets and makes it a valuable tool for integrating data-driven models into decision-making processes for material design and analysis. For example, one can use this workflow to quantify grain size distributions at varying processing conditions like temperature and pressure and using that knowledge adjust processing conditions to achieve desired superlattice orientations and grain sizes.