Matthew P. Castanier

Zhiling Chen, David Gorsich, Matthew P. Castanier et al.

Robotic laser profiling is widely used for dimensional verification and surface inspection, yet measurement fidelity is often dominated by sensor configuration rather than robot motion. Industrial profilers expose multiple coupled parameters, including sampling frequency, measurement range, exposure time, receiver dynamic range, and illumination, that are still tuned by trial-and-error; mismatches can cause saturation, clipping, or missing returns that cannot be recovered downstream. We formulate instruction-conditioned sensing parameter recommendation; given a pre-scan RGB observation and a natural-language inspection instruction, infer a discrete configuration over key parameters of a robot-mounted profiler. To benchmark this problem, we develop Instruct-Obs2Param, a real-world multimodal dataset linking inspection intents and multi-view pose and illumination variation across 16 objects to canonical parameter regimes. We then propose ScanHD, a hyperdimensional computing framework that binds instruction and observation into a task-aware code and performs parameter-wise associative reasoning with compact memories, matching discrete scanner regimes while yielding stable, interpretable, low-latency decisions. On Instruct-Obs2Param, ScanHD achieves 92.7% average exact accuracy and 98.1% average Win@1 accuracy across the five parameters, with strong cross-split generalization and low-latency inference suitable for deployment, outperforming rule-based heuristics, conventional multimodal models, and multimodal large language models. This work enables autonomous, instruction-conditioned sensing configuration from task intent and scene context, eliminating manual tuning and elevating sensor configuration from a static setting to an adaptive decision variable.

Jingzhan Ge, Ajeeth Vellore, Ajinkya Palwe et al.

Multiphoton photoreduction enables high-fidelity fabrication of complex 3D microstructures, yet reliable process-structure-property (PSP) prediction remains difficult because the available data are sparse, heterogeneous, and interaction-dominated. In this regime, conventional feature-vector models are statistically underdetermined, making them prone to spurious correlations, poor regime transfer, and unstable post hoc explanations, whereas mechanistic pipelines depend on calibrated submodels that are rarely available during early process development. We present PSP-HDC, a graph-structured hyperdimensional computing framework that encodes a directed PSP graph as an internal prior for representation, inference, and explanation. A trainable scalar-to-hypervector encoder learns parameter-specific embeddings on a fixed hyperdimensional basis to accommodate heterogeneous scales and noise. Sample representations are then composed through graph-aligned binding and bundling along directed PSP dependencies, and prediction is performed by associative-memory retrieval against class prototypes. Because the same prototype memories support both decision making and attribution, PSP-HDC provides intrinsic explanations at the parameter, group, and within-group levels, while memory alignment and separation quantify prototype formation during training. On sheet-resistance regime prediction for the 3D platform, PSP-HDC achieves an accuracy of 0.910 +/- 0.077 over 1000 random splits and 0.896 under process-fold generalization, outperforming strong baselines.

Danny Hoang, Ryan Matthiessen, Christopher Miller et al.

High-precision CNC machining of free-form aerospace components requires bounded compensations informed by inspection, simulation, and process knowledge. Off-the-shelf large language model (LLM) assistants can generate text, but they do not reliably execute risk-constrained multi-step numerical workflows or provide auditable provenance for high-stakes decisions. We present multi-agent knowledge analysis (MAKA), a human-in-the-loop decision-support architecture that separates intent routing, tools-only quantitative analysis, knowledge graph retrieval, and critic-based verification that enforces physical plausibility, safety bounds, and provenance completeness before recommendations are surfaced for human approval. MAKA is instantiated on a Ti-6Al-4V rotor blade machining testbed by fusing virtual-machining path-tracking error fields, cutting-force and deflection simulations, and scan-based 3D inspection deviation maps from 16 blades. The analysis decomposes deviation into an evidence-linked pathing component, a drift-based wear proxy capturing systematic evolution across parts, a residual systematic compliance term, and a variability proxy for instability-aware escalation. In a three-level tool-orchestration benchmark (single-step through $\geq$3-step stateful sequences), MAKA improves successful tool execution by up to 87.5 percentage points relative to an unstructured single-model interaction pattern with identical tool access. Digital twin what-if studies show MAKA can coordinate traceable compensation candidates that reduce predicted surface deviation from order $10^{-2}$in to approximately $\pm 10^{-3}$in over most of the blade within the simulation environment, providing a pre-deployment verification signal for risk-aware human decision-making.

Zhiling Chen, David Gorsich, Matthew P. Castanier et al.

Robotic inspection relies on accurate sensing to acquire high-fidelity geometric measurements for defect detection and metrology. While prior work has focused on robot motion and viewpoint planning, how to configure sensing parameters remains largely underexplored, despite their decisive impact on measurement quality. We propose SenseHD, a robotic sensing system that formulates scanner configuration as an instruction-conditioned sensing decision. Instead of predicting precise parameter values, SenseHD treats sensing parameters as discrete sensing actions and selects stable sensing regimes through hyperdimensional associative memory. Experiments on a real robotic inspection platform demonstrate that SenseHD robustly selects appropriate sensing configurations and significantly improves inspection reliability, while remaining lightweight and efficient compared to baseline methods.

Danny Hoang, David Gorsich, Matthew P. Castanier et al.

Precision process planning in Computer Numerical Control (CNC) machining demands rapid, context-aware decisions on tool selection, feed-speed pairs, and multi-axis routing, placing immense cognitive and procedural burdens on engineers from design specification through final part inspection. Conventional rule-based computer-aided process planning and knowledge-engineering shells freeze domain know-how into static tables, which become limited when dealing with unseen topologies, novel material states, shifting cost-quality-sustainability weightings, or shop-floor constraints such as tool unavailability and energy caps. Large language models (LLMs) promise flexible, instruction-driven reasoning for tasks but they routinely hallucinate numeric values and provide no provenance. We present Augmented Retrieval Knowledge Network Enhanced Search & Synthesis (ARKNESS), the end-to-end framework that fuses zero-shot Knowledge Graph (KG) construction with retrieval-augmented generation to deliver verifiable, numerically exact answers for CNC process planning. ARKNESS (1) automatically distills heterogeneous machining documents, G-code annotations, and vendor datasheets into augmented triple, multi-relational graphs without manual labeling, and (2) couples any on-prem LLM with a retriever that injects the minimal, evidence-linked subgraph needed to answer a query. Benchmarked on 155 industry-curated questions spanning tool sizing and feed-speed optimization, a lightweight 3B-parameter Llama-3 augmented by ARKNESS matches GPT-4o accuracy while achieving a +25 percentage point gain in multiple-choice accuracy, +22.4 pp in F1, and 8.1x ROUGE-L on open-ended responses.

Bo Fu, Tribhi Kathuria, Denise Rizzo et al.

This work presents a framework for multi-robot tour guidance in a partially known environment with uncertainty, such as a museum. In the proposed centralized multi-robot planner, a simultaneous matching and routing problem (SMRP) is formulated to match the humans with robot guides according to their selected places of interest (POIs) and generate the routes and schedules for the robots according to uncertain spatial and time estimation. A large neighborhood search algorithm is developed to efficiently find sub-optimal low-cost solutions for the SMRP. The scalability and optimality of the multi-robot planner are evaluated computationally under different numbers of humans, robots, and POIs. The largest case tested involves 50 robots, 250 humans, and 50 POIs. Then, a photo-realistic multi-robot simulation platform was developed based on Habitat-AI to verify the tour guiding performance in an uncertain indoor environment. Results demonstrate that the proposed centralized tour planner is scalable, makes a smooth trade-off in the plans under different environmental constraints, and can lead to robust performance with inaccurate uncertainty estimations (within a certain margin).

Bo Fu, William Smith, Denise Rizzo et al.

This paper develops a stochastic programming framework for multi-agent systems where task decomposition, assignment, and scheduling problems are simultaneously optimized. The framework can be applied to heterogeneous mobile robot teams with distributed sub-tasks. Examples include pandemic robotic service coordination, explore and rescue, and delivery systems with heterogeneous vehicles. Due to their inherent flexibility and robustness, multi-agent systems are applied in a growing range of real-world problems that involve heterogeneous tasks and uncertain information. Most previous works assume one fixed way to decompose a task into roles that can later be assigned to the agents. This assumption is not valid for a complex task where the roles can vary and multiple decomposition structures exist. Meanwhile, it is unclear how uncertainties in task requirements and agent capabilities can be systematically quantified and optimized under a multi-agent system setting. A representation for complex tasks is proposed: agent capabilities are represented as a vector of random distributions, and task requirements are verified by a generalizable binary function. The conditional value at risk (CVaR) is chosen as a metric in the objective function to generate robust plans. An efficient algorithm is described to solve the model, and the whole framework is evaluated in two different practical test cases: capture-the-flag and robotic service coordination during a pandemic (e.g., COVID-19). Results demonstrate that the framework is generalizable, scalable up to 140 agents and 40 tasks for the example test cases, and provides low-cost plans that ensure a high probability of success.

Bo Fu, William Smith, Denise Rizzo et al.

For robot swarms operating on complex missions in an uncertain environment, it is important that the decision-making algorithm considers both heterogeneity and uncertainty. This paper presents a stochastic programming framework for the vehicle routing problem with stochastic travel energy costs and heterogeneous vehicles and tasks. We represent the heterogeneity as linear constraints, estimate the uncertain energy cost through Gaussian process regression, formulate this stochasticity as chance constraints or stochastic recourse costs, and then solve the stochastic programs using branch and cut algorithms to minimize the expected energy cost. The performance and practicality are demonstrated through extensive computational experiments and a practical test case.