Farhad Imani

Zhiling Chen, Hanning Chen, Mohsen Imani et al.

Workplace accidents due to personal protective equipment (PPE) non-compliance raise serious safety concerns and lead to legal liabilities, financial penalties, and reputational damage. While object detection models have shown the capability to address this issue by identifying safety items, most existing models, such as YOLO, Faster R-CNN, and SSD, are limited in verifying the fine-grained attributes of PPE across diverse workplace scenarios. Vision language models (VLMs) are gaining traction for detection tasks by leveraging the synergy between visual and textual information, offering a promising solution to traditional object detection limitations in PPE recognition. Nonetheless, VLMs face challenges in consistently verifying PPE attributes due to the complexity and variability of workplace environments, requiring them to interpret context-specific language and visual cues simultaneously. We introduce Clip2Safety, an interpretable detection framework for diverse workplace safety compliance, which comprises four main modules: scene recognition, the visual prompt, safety items detection, and fine-grained verification. The scene recognition identifies the current scenario to determine the necessary safety gear. The visual prompt formulates the specific visual prompts needed for the detection process. The safety items detection identifies whether the required safety gear is being worn according to the specified scenario. Lastly, the fine-grained verification assesses whether the worn safety equipment meets the fine-grained attribute requirements. We conduct real-world case studies across six different scenarios. The results show that Clip2Safety not only demonstrates an accuracy improvement over state-of-the-art question-answering based VLMs but also achieves inference times two hundred times faster.

Danny Hoang, Anandkumar Patel, Ruimen Chen et al.

Smart manufacturing can significantly improve efficiency and reduce energy consumption, yet the energy demands of AI models may offset these gains. This study utilizes in-situ sensing-based prediction of geometric quality in smart machining to compare the energy consumption, accuracy, and speed of common AI models. HyperDimensional Computing (HDC) is introduced as an alternative, achieving accuracy comparable to conventional models while drastically reducing energy consumption, 200$\times$ for training and 175 to 1000$\times$ for inference. Furthermore, HDC reduces training times by 200$\times$ and inference times by 300 to 600$\times$, showcasing its potential for energy-efficient smart manufacturing.

Fardin Jalil Piran, Prathyush P. Poduval, Hamza Errahmouni Barkam et al.

Machine Learning (ML) models integrated with in-situ sensing offer transformative solutions for defect detection in Additive Manufacturing (AM), but this integration brings critical challenges in safeguarding sensitive data, such as part designs and material compositions. Differential Privacy (DP), which introduces mathematically controlled noise, provides a balance between data utility and privacy. However, black-box Artificial Intelligence (AI) models often obscure how this noise impacts model accuracy, complicating the optimization of privacy-accuracy trade-offs. This study introduces the Differential Privacy-Hyperdimensional Computing (DP-HD) framework, a novel approach combining Explainable AI (XAI) and vector symbolic paradigms to quantify and predict noise effects on accuracy using a Signal-to-Noise Ratio (SNR) metric. DP-HD enables precise tuning of DP noise levels, ensuring an optimal balance between privacy and performance. The framework has been validated using real-world AM data, demonstrating its applicability to industrial environments. Experimental results demonstrate DP-HD's capability to achieve state-of-the-art accuracy (94.43%) with robust privacy protections in anomaly detection for AM, even under significant noise conditions. Beyond AM, DP-HD holds substantial promise for broader applications in privacy-sensitive domains such as healthcare, financial services, and government data management, where securing sensitive data while maintaining high ML performance is paramount.

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.

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.

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, Hanning Chen, Mohsen Imani et al.

In industrial settings, the accurate detection of anomalies is essential for maintaining product quality and ensuring operational safety. Traditional industrial anomaly detection (IAD) models often struggle with flexibility and adaptability, especially in dynamic production environments where new defect types and operational changes frequently arise. Recent advancements in Multimodal Large Language Models (MLLMs) hold promise for overcoming these limitations by combining visual and textual information processing capabilities. MLLMs excel in general visual understanding due to their training on large, diverse datasets, but they lack domain-specific knowledge, such as industry-specific defect tolerance levels, which limits their effectiveness in IAD tasks. To address these challenges, we propose Echo, a novel multi-expert framework designed to enhance MLLM performance for IAD. Echo integrates four expert modules: Reference Extractor which provides a contextual baseline by retrieving similar normal images, Knowledge Guide which supplies domain-specific insights, Reasoning Expert which enables structured, stepwise reasoning for complex queries, and Decision Maker which synthesizes information from all modules to deliver precise, context-aware responses. Evaluated on the MMAD benchmark, Echo demonstrates significant improvements in adaptability, precision, and robustness, moving closer to meeting the demands of real-world industrial anomaly detection.

Fardin Jalil Piran, Zhiling Chen, Mohsen Imani et al.

Federated Learning (FL) has become a key method for preserving data privacy in Internet of Things (IoT) environments, as it trains Machine Learning (ML) models locally while transmitting only model updates. Despite this design, FL remains susceptible to threats such as model inversion and membership inference attacks, which can reveal private training data. Differential Privacy (DP) techniques are often introduced to mitigate these risks, but simply injecting DP noise into black-box ML models can compromise accuracy, particularly in dynamic IoT contexts, where continuous, lifelong learning leads to excessive noise accumulation. To address this challenge, we propose Federated HyperDimensional computing with Privacy-preserving (FedHDPrivacy), an eXplainable Artificial Intelligence (XAI) framework that integrates neuro-symbolic computing and DP. Unlike conventional approaches, FedHDPrivacy actively monitors the cumulative noise across learning rounds and adds only the additional noise required to satisfy privacy constraints. In a real-world application for monitoring manufacturing machining processes, FedHDPrivacy maintains high performance while surpassing standard FL frameworks - Federated Averaging (FedAvg), Federated Proximal (FedProx), Federated Normalized Averaging (FedNova), and Federated Optimization (FedOpt) - by up to 37%. Looking ahead, FedHDPrivacy offers a promising avenue for further enhancements, such as incorporating multimodal data fusion.

Yang Zhang, Qianyu Zhou, Farhad Imani et al.

Wind turbine blades operate in harsh environments, making timely damage detection essential for preventing failures and optimizing maintenance. Drone-based inspection and deep learning are promising, but typically depend on large, labeled datasets, which limit their ability to detect rare or evolving damage types. To address this, we propose a zero-shot-oriented inspection framework that integrates Retrieval-Augmented Generation (RAG) with Vision-Language Models (VLM). A multimodal knowledge base is constructed, comprising technical documentation, representative reference images, and domain-specific guidelines. A hybrid text-image retriever with keyword-aware reranking assembles the most relevant context to condition the VLM at inference, injecting domain knowledge without task-specific training. We evaluate the framework on 30 labeled blade images covering diverse damage categories. Although the dataset is small due to the difficulty of acquiring verified blade imagery, it covers multiple representative defect types. On this test set, the RAG-grounded VLM correctly classified all samples, whereas the same VLM without retrieval performed worse in both accuracy and precision. We further compare against open-vocabulary baselines and incorporate uncertainty Clopper-Pearson confidence intervals to account for the small-sample setting. Ablation studies indicate that the key advantage of the framework lies in explainability and generalizability: retrieved references ground the reasoning process and enable the detection of previously unseen defects by leveraging domain knowledge rather than relying solely on visual cues. This research contributes a data-efficient solution for industrial inspection that reduces dependence on extensive labeled datasets.

Fardin Jalil Piran, Anandkumar Patel, Rajiv Malhotra et al.

Smart manufacturing requires on-device intelligence that meets strict latency and energy budgets. HyperDimensional Computing (HDC) offers a lightweight alternative by encoding data as high-dimensional hypervectors and computing with simple operations. Prior studies often assume that the qualitative relation between HDC hyperparameters and performance is stable across applications. Our analysis of two representative tasks, signal-based quality monitoring in Computer Numerical Control (CNC) machining and image-based defect detection in Laser Powder Bed Fusion (LPBF), shows that this assumption does not hold. We map how encoder type, projection variance, hypervector dimensionality, and data regime shape accuracy, inference latency, training time, and training energy. A formal complexity model explains predictable trends in encoding and similarity computation and reveals nonmonotonic interactions with retraining that preclude a closed-form optimum. Empirically, signals favor nonlinear Random Fourier Features with more exclusive encodings and saturate in accuracy beyond moderate dimensionality. Images favor linear Random Projection, achieve high accuracy with small dimensionality, and depend more on sample count than on dimensionality. Guided by these insights, we tune HDC under multiobjective constraints that reflect edge deployment and obtain models that match or exceed the accuracy of state-of-the-art deep learning and Transformer models while delivering at least 6x faster inference and more than 40x lower training energy. These results demonstrate that domain-aware HDC encoding is necessary and that tuned HDC offers a practical, scalable path to real-time industrial AI on constrained hardware. Future work will enable adaptive encoder and hyperparameter selection, expand evaluation to additional manufacturing modalities, and validate on low-power accelerators.

Fardin Jalil Piran, Zhiling Chen, Yang Zhang et al.

Decentralized federated learning faces privacy risks because model updates can leak data through inference attacks and membership inference, a concern that grows over many client exchanges. Differential privacy offers principled protection by injecting calibrated noise so confidential information remains secure on resource-limited IoT devices. Yet without transparency, black-box training cannot track noise already injected by previous clients and rounds, which forces worst-case additions and harms accuracy. We propose PrivateDFL, an explainable framework that joins hyperdimensional computing with differential privacy and keeps an auditable account of cumulative noise so each client adds only the difference between the required noise and what has already been accumulated. We evaluate on MNIST, ISOLET, and UCI-HAR to span image, signal, and tabular modalities, and we benchmark against transformer-based and deep learning-based baselines trained centrally with Differentially Private Stochastic Gradient Descent (DP-SGD) and Renyi Differential Privacy (RDP). PrivateDFL delivers higher accuracy, lower latency, and lower energy across IID and non-IID partitions while preserving formal (epsilon, delta) guarantees and operating without a central server. For example, under non-IID partitions, PrivateDFL achieves 24.42% higher accuracy than the Vision Transformer on MNIST while using about 10x less training time, 76x lower inference latency, and 11x less energy, and on ISOLET it exceeds Transformer accuracy by more than 80% with roughly 10x less training time, 40x lower inference latency, and 36x less training energy. Future work will extend the explainable accounting to adversarial clients and adaptive topologies with heterogeneous privacy budgets.

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.

Kiarash Naghavi Khanghah, Zhiling Chen, Lela Romeo et al.

Additive manufacturing enables the fabrication of complex designs while minimizing waste, but faces challenges related to defects and process anomalies. This study presents a novel multimodal Retrieval-Augmented Generation-based framework that automates anomaly detection across various Additive Manufacturing processes leveraging retrieved information from literature, including images and descriptive text, rather than training datasets. This framework integrates text and image retrieval from scientific literature and multimodal generation models to perform zero-shot anomaly identification, classification, and explanation generation in a Laser Powder Bed Fusion setting. The proposed framework is evaluated on four L-PBF manufacturing datasets from Oak Ridge National Laboratory, featuring various printer makes, models, and materials. This evaluation demonstrates the framework's adaptability and generalizability across diverse images without requiring additional training. Comparative analysis using Qwen2-VL-2B and GPT-4o-mini as MLLM within the proposed framework highlights that GPT-4o-mini outperforms Qwen2-VL-2B and proportional random baseline in manufacturing anomalies classification. Additionally, the evaluation of the RAG system confirms that incorporating retrieval mechanisms improves average accuracy by 12% by reducing the risk of hallucination and providing additional information. The proposed framework can be continuously updated by integrating emerging research, allowing seamless adaptation to the evolving landscape of AM technologies. This scalable, automated, and zero-shot-capable framework streamlines AM anomaly analysis, enhancing efficiency and accuracy.

Zhuowen Zou, Haleh Alimohamadi, Farhad Imani et al.

Recently, brain-inspired computing models have shown great potential to outperform today's deep learning solutions in terms of robustness and energy efficiency. Particularly, Spiking Neural Networks (SNNs) and HyperDimensional Computing (HDC) have shown promising results in enabling efficient and robust cognitive learning. Despite the success, these two brain-inspired models have different strengths. While SNN mimics the physical properties of the human brain, HDC models the brain on a more abstract and functional level. Their design philosophies demonstrate complementary patterns that motivate their combination. With the help of the classical psychological model on memory, we propose SpikeHD, the first framework that fundamentally combines Spiking neural network and hyperdimensional computing. SpikeHD generates a scalable and strong cognitive learning system that better mimics brain functionality. SpikeHD exploits spiking neural networks to extract low-level features by preserving the spatial and temporal correlation of raw event-based spike data. Then, it utilizes HDC to operate over SNN output by mapping the signal into high-dimensional space, learning the abstract information, and classifying the data. Our extensive evaluation on a set of benchmark classification problems shows that SpikeHD provides the following benefit compared to SNN architecture: (1) significantly enhance learning capability by exploiting two-stage information processing, (2) enables substantial robustness to noise and failure, and (3) reduces the network size and required parameters to learn complex information.