Search Results (2,200)

Recently, diffractive optics systems have garnered increasing attention due to their myriad benefits in various applications, such as creating vortex beams, Bessel beams, or optical traps, while refractive optics systems still exhibit some disadvantages related to materials, substrates, and intensity shapes. The manufacturing of diffractive optical elements has become easier due to the development of lithography techniques such as direct laser writing, photo lithography, and electron beam lithography. In this paper, we improve the results from previous research and propose a new methodology to design and fabricate advanced binary diffractive optical elements that achieve a square focal spot independently, reducing reliance on additional components. By integrating a binary square zone plate with an axicon zone plate of the same scale, we employ machine learning for laser path optimization and direct laser lithography for manufacturing. This streamlined approach enhances simplicity, accuracy, efficiency, and cost effectiveness. Our upgraded binary diffractive optical elements are ready for real-world applications, marking a significant improvement in optical capabilities. Full article

The development of Industry 4.0 has accelerated the adoption of sophisticated technologies, including Digital Twins (DTs), Artificial Intelligence (AI), and cybersecurity, within Additive Manufacturing (AM). Enabling real-time monitoring, process optimization, predictive maintenance, and secure data management can redefine conventional manufacturing paradigms. Although their individual importance is increasing, a consistent understanding of how these technologies interact and collectively improve AM procedures is lacking. Focusing on the integration of digital twins (DTs), modular AI, and cybersecurity in AM, this review presents a comprehensive analysis of over 137 research publications from Scopus, Web of Science, Google Scholar, and ResearchGate. The publications are categorized into three thematic groups, followed by an analysis of key findings. Finally, the study identifies research gaps and proposes detailed recommendations along with a framework for future research. The study reveals that traditional AM processes have undergone significant transformations driven by digital threads, digital threads (DTs), and AI. However, this digitalization introduces vulnerabilities, leaving AM systems prone to cyber-physical attacks. Emerging advancements in AI, Machine Learning (ML), and Blockchain present promising solutions to mitigate these challenges. This paper is among the first to comprehensively summarize and evaluate the advancements in AM, emphasizing the integration of DTs, Modular AI, and cybersecurity strategies. Full article

Automatic component recognition plays a crucial role in intelligent ship manufacturing, but existing methods suffer from low recognition accuracy and high computational cost in industrial scenarios involving small samples, component stacking, and diverse categories. To address the requirements of shipbuilding industrial applications, a Triplet Spatial Reconstruction Attention (TSA) mechanism that combines threshold-based feature separation with triplet parallel processing is proposed, and a lightweight You Only Look Once Ship (YOLO-Ship) detection network is constructed. Unlike existing attention mechanisms that focus on either spatial reconstruction or channel attention independently, the proposed TSA integrates triplet parallel processing with spatial feature separation–reconstruction techniques to achieve enhanced target feature representation while significantly reducing parameter count and computational overhead. Experimental validation on a small-scale actual ship component dataset demonstrates that the improved network achieves 88.7% mean Average Precision (mAP), 84.2% precision, and 87.1% recall, representing improvements of 3.5%, 2.2%, and 3.8%, respectively, compared to the original YOLOv8n algorithm, requiring only 2.6 M parameters and 7.5 Giga Floating-point Operations per Second (GFLOPs) computational cost, achieving a good balance between detection accuracy and lightweight model design. Future research directions include developing adaptive threshold learning mechanisms for varying industrial conditions and integration with surface defect detection capabilities to enhance comprehensive quality control in intelligent manufacturing systems. Full article

The integration of machine learning (ML) into industrial automation is fundamentally reshaping how manufacturing systems are monitored, inspected, and optimized. By applying machine learning to real-time sensor data and operational histories, advanced models enable proactive fault prediction, intelligent inspection, and dynamic process control—directly enhancing system reliability, product quality, and efficiency. This review explores the transformative role of ML across three key domains: Predictive Maintenance (PdM), Quality Control (QC), and Process Optimization (PO). It also analyzes how Digital Twin (DT) and Edge AI technologies are expanding the practical impact of ML in these areas. Our analysis reveals a marked rise in deep learning, especially convolutional and recurrent architectures, with a growing shift toward real-time, edge-based deployment. The paper also catalogs the datasets used, the tools and sensors employed for data collection, and the industrial software platforms supporting ML deployment in practice. This review not only maps the current research terrain but also highlights emerging opportunities in self-learning systems, federated architectures, explainable AI, and themes such as self-adaptive control, collaborative intelligence, and autonomous defect diagnosis—indicating that ML is poised to become deeply embedded across the full spectrum of industrial operations in the coming years. Full article

Automated surface defect detection in steel manufacturing is pivotal for ensuring product quality, yet it remains an open challenge owing to the extreme heterogeneity of defect morphologies—ranging from hairline cracks and microscopic pores to elongated scratches and shallow dents. Existing approaches, whether classical vision pipelines or recent deep-learning paradigms, struggle to simultaneously satisfy the stringent demands of industrial scenarios: high accuracy on sub-millimeter flaws, insensitivity to texture-rich backgrounds, and real-time throughput on resource-constrained hardware. Although contemporary detectors have narrowed the gap, they still exhibit pronounced sensitivity–robustness trade-offs, particularly in the presence of scale-varying defects and cluttered surfaces. To address these limitations, we introduce MBY (MBDNet-Attention-YOLO), a lightweight yet powerful framework that synergistically couples the MBDNet backbone with the YOLO detection head. Specifically, the backbone embeds three novel components: (1) HGStem, a hierarchical stem block that enriches low-level representations while suppressing redundant activations; (2) Dynamic Align Fusion (DAF), an adaptive cross-scale fusion mechanism that dynamically re-weights feature contributions according to defect saliency; and (3) C2f-DWR, a depth-wise residual variant that progressively expands receptive fields without incurring prohibitive computational costs. Building upon this enriched feature hierarchy, the neck employs our proposed MultiSEAM module—a cascaded squeeze-and-excitation attention mechanism operating at multiple granularities—to harmonize fine-grained and semantic cues, thereby amplifying weak defect signals against complex textures. Finally, we integrate the Inner-SIoU loss, which refines the geometric alignment between predicted and ground-truth boxes by jointly optimizing center distance, aspect ratio consistency, and IoU overlap, leading to faster convergence and tighter localization. Extensive experiments on two publicly available steel-defect benchmarks—NEU-DET and PVEL-AD—demonstrate the superiority of MBY. Without bells and whistles, our model achieves 85.8% mAP@0.5 on NEU-DET and 75.9% mAP@0.5 on PVEL-AD, surpassing the best-reported results by significant margins while maintaining real-time inference on an NVIDIA Jetson Xavier. Ablation studies corroborate the complementary roles of each component, underscoring MBY’s robustness across defect scales and surface conditions. These results suggest that MBY strikes an appealing balance between accuracy, efficiency, and deployability, offering a pragmatic solution for next-generation industrial quality-control systems. Full article

Collagen implants in neurosurgery are widely used due to their biocompatibility, biodegradability, and ability to support tissue regeneration, but their mechanical properties, such as low tensile strength and susceptibility to enzymatic degradation, remain challenging. Current technologies are improving these implants through cross-linking, synthetic reinforcements, and advanced manufacturing techniques such as 3D bioprinting to improve durability and predictability. Industry 4.0 is contributing to this by automating production, using data analytics and machine learning to optimize implant properties and ensure quality control. In Industry 5.0, the focus is shifting to personalization, enabling the creation of patient-specific implants through human–machine collaboration and advanced biofabrication. eHealth integrates digital monitoring systems, enabling real-time tracking of implant healing and performance to inform personalized care. Despite progress, challenges such as cost, material property variability, and scalability for mass production remain. The future lies in smart biomaterials, AI-driven design, and precision biofabrication, which could mean the possibility of creating more effective, accessible, and patient-specific collagen implants. The aim of this article is to examine the current state and determine the prospects for the development of mechanical properties of collagen implant used in neurosurgery towards Industry 4.0/5.0, including ML model. Full article

Mixed-flow assembly lines are widely employed in industrial manufacturing to handle diverse production tasks. For mixed flow assembly lines that involve mold changes and greater processing difficulties, there are currently two approaches: batch production and production according to order sequence. The first approach struggles to meet the processing constraints of workpieces with higher production difficulty, while the second approach requires the development of suitable scheduling schemes to balance mold changes and continuous processing. Therefore, under the second approach, developing an excellent scheduling scheme is a challenging problem. This study addresses the mixed-flow assembly shop scheduling problem, considering continuous processing and mold-changing constraints, by developing a multi-objective optimization model to minimize additional production time and customer waiting time. As this NP-hard problem poses significant challenges in solution space exploration, the conventional NSGA-II algorithm suffers from limited local search capability. To address this, we propose an enhanced NSGA-II algorithm (RLVNS-NSGA-II) integrating deep reinforcement learning. Our approach combines multiple neighborhood search operators with deep reinforcement learning, which dynamically utilizes population diversity and objective function data to guide and strengthen local search. Simulation experiments confirm that the proposed algorithm surpasses existing methods in local search performance. Compared to VNS-NSGA-II and SVNS-NSGA-II, the RLVNS-NSGA-II algorithm achieved hypervolume improvements ranging from 19.72% to 42.88% and 12.63% to 31.19%, respectively. Full article

In this work, Laser Powder Bed Fusion (LPBF), an additive manufacturing (AM) process, was optimised to produce pure magnesium components. The focus of the presented work is on the prediction of the relative product density using the machine learning model XGBoost to improve the production process and thus the usability of the material for practical use. Experimental tests with different parameters, laser power, scanning speed and layer thickness, and fixed parameters, track overlapping and hatching distance, were analysed and resulted in relative material densities between 89.29% and 99.975%. The XGBoost model showed high predictive power, achieving an R² test result of 0.835, a mean absolute error (MAE) of 0.728 and a root mean square error (RMSE) of 0.982. Feature importance analysis showed that the interaction of laser power and scanning speed had the largest influence on the predictions at 35.9%, followed by laser power × layer thickness at 29.0%. The individual contributions were laser power (11.8%), scanning speed (10.7%), scanning speed × layer thickness (9.0%) and layer thickness (3.6%). These results provide a data-based method for LPBF parameter settings that improve manufacturing efficiency and component performance in the aerospace, automotive and biomedical industries and identify optimal parameter regions for a high density, serving as a pre-optimisation stage. Full article

Accurate melt pool geometry prediction is essential for ensuring quality and reliability in Laser Powder Bed Fusion (L-PBF). However, small experimental datasets and limited physical interpretability often restrict the effectiveness of traditional machine learning (ML) models. This study proposes a hybrid framework that integrates an explicit thermal model with ML algorithms to improve prediction under sparse data conditions. The explicit model—calibrated for variable penetration depth and absorptivity—generates synthetic melt pool data, augmenting 36 experimental samples across conduction, transition, and keyhole regimes for 316 L stainless steel. Three ML methods—Multilayer Perceptron (MLP), Random Forest, and XGBoost—are trained using fivefold cross-validation. The hybrid approach significantly improves prediction accuracy, especially in unstable transition regions (D/W ≈ 0.5–1.2), where morphological fluctuations hinder experimental sampling. The best-performing model (MLP) achieves R² > 0.98, with notable reductions in MAE and RMSE. The results highlight the benefit of incorporating physically consistent, nonlinearly distributed synthetic data to enhance generalization and robustness. This physics-augmented learning strategy not only demonstrates scientific novelty by integrating mechanistic modeling into data-driven learning, but also provides a scalable solution for intelligent process optimization, in situ monitoring, and digital twin development in metal additive manufacturing. Full article

Shift organizations in automotive manufacturing often rely on manual task allocation, resulting in inefficiencies, human error, and increased workload for supervisors. This research introduces an automated solution using the Kuhn-Munkres algorithm, integrated with the Moodle learning management system, to optimize task assignments based on operator qualifications and task complexity. Simulations conducted with real industrial data demonstrate that the proposed method meets operational requirements, both logically and mathematically. The system improves the start of shifts by assigning simpler tasks initially, enhancing operator confidence and reducing the need for assistance. It also ensures that task assignments align with required training levels, improving quality and process reliability. For industrial practitioners, the approach provides a practical tool to reduce planning time, human error, and supervisory burden, while increasing shift productivity. From an academic perspective, the study contributes to applied operations research and workforce optimization, offering a replicable model grounded in real-world applications. The integration of algorithmic task allocation with training systems enables a more accurate matching of workforce capabilities to production demands. This study aims to support data-driven decision-making in shift management, with the potential to enhance operational efficiency and encourage timely start of work, thereby possibly contributing to smoother production flow and improved organizational performance. Full article

Work-related musculoskeletal disorders (WMSDs) are a leading concern in industrial ergonomics, often stemming from sustained non-neutral postures and repetitive tasks. This paper presents a vision-based framework for real-time, frame-level ergonomic risk classification using a lightweight Vision Transformer (ViT). The proposed system operates directly on raw RGB images without requiring skeleton reconstruction, joint angle estimation, or image segmentation. A single ViT model simultaneously classifies eight anatomical regions, enabling efficient multi-label posture assessment. Training is supervised using a multimodal dataset acquired from synchronized RGB video and full-body inertial motion capture, with ergonomic risk labels derived from RULA scores computed on joint kinematics. The system is validated on realistic, simulated industrial tasks that include common challenges such as occlusion and posture variability. Experimental results show that the ViT model achieves state-of-the-art performance, with F1-scores exceeding 0.99 and AUC values above 0.996 across all regions. Compared to previous CNN-based system, the proposed model improves classification accuracy and generalizability while reducing complexity and enabling real-time inference on edge devices. These findings demonstrate the model’s potential for unobtrusive, scalable ergonomic risk monitoring in real-world manufacturing environments. Full article

In response to the low efficiency of collaborative processing of sewing machine cases at the part level in network collaborative manufacturing, this paper proposes a sewing machine cases manufacturing service composition optimization method based on an improved multi-objective artificial hummingbird algorithm. The structure and production process of sewing machine cases are analyzed; a framework for service composition optimization in the sewing machine cases manufacturing service platform is established; the required manufacturing resource service composition is determined; and a dual-objective service composition optimization mathematical model that considers Quality of Service (QoS) indicators and flexibility indicators is constructed. Opposition-based learning strategies, roulette wheel selection strategies, and improved differential evolution strategies are embedded in the multi-objective artificial hummingbird algorithm, and the improved artificial hummingbird algorithm (ORAHA_DE) is used to solve the sewing machine cases manufacturing service composition optimization model. The experimental results show the effectiveness and superiority of this composition optimization method in solving the sewing machine cases manufacturing composition optimization problem while avoiding entrapment in a local optimum during the solution process, thereby achieving the composition optimization of sewing machine cases collaborative manufacturing services. Full article

Internal crack defects in high-strength low-alloy (HSLA) steels during continuous casting pose significant challenges to downstream processing and product reliability. However, due to the inherent class imbalance in industrial defect datasets, conventional machine learning models often suffer from poor sensitivity to minority class instances. This study proposes a predictive framework that integrates conditional tabular generative adversarial network (CTGAN) for synthetic minority sample generation and CatBoost for classification. A dataset of 733 process records was collected from a continuous caster, and 25 informative features were selected using mutual information. CTGAN was employed to augment the minority class (crack) samples, achieving a balanced training set. Feature distribution analysis and principal component visualization indicated that the synthetic data effectively preserved the statistical structure of the original minority class. Compared with the other machine learning methods, including KNN, SVM, and MLP, CatBoost achieved the highest metrics, with an accuracy of 0.9239, precision of 0.9041, recall of 0.9018, and F1-score of 0.9022. Results show that CTGAN-based augmentation improves classification performance across all models. These findings highlight the effectiveness of GAN-based augmentation for imbalanced industrial data and validate the CTGAN–CatBoost model as a robust solution for online defect prediction in steel manufacturing. Full article

One concern in the yearly re-formulation of influenza vaccines is the time-consuming manufacturing of vaccine potency reagents, particularly for emergency responses. The continuous evaluation of modern techniques such as reversed-phase (RP) chromatography is an asset for streamlining this process. One challenge with RP methods, however, is the need to re-optimize methods for antigens that show poor separation, which can be highly dependent on analyst experience and available data. In this study, we leveraged a large RP dataset of influenza antigens to explore machine learning (ML) approaches of classifying challenging separations for computer-assisted method re-optimization across years, products, and analysts. Methods: To address recurring chromatographic issues—such as poor resolution, strain co-elution, and signal absence—we applied data augmentation techniques to correct class imbalance and trained multiple supervised ML classifiers to distinguish between these peak profiles. Results: With data augmentation, several ML models demonstrated promising accuracy in classifying chromatographic profiles according to the provided labels. These models effectively distinguished patterns indicative of separation issues in real-world data. Conclusions Our findings highlight the potential of ML as a computer assisted tool in the evaluation of vaccine quality, offering a scalable and objective approach to chromatogram classification. By reducing reliance on manual interpretation, ML can expedite the optimization of analytical methods, which is particularly needed for rapid responses. Future research involving larger, inter-laboratory datasets will further elucidate the utility of ML in vaccine analysis. Full article

The convergence of artificial intelligence (AI) and nanomedicine has transformed cancer vaccine development, particularly in optimizing RNA-loaded lipid nanoparticles (LNPs). Stability and targeted delivery are major obstacles to the clinical translation of promising RNA-LNP vaccines for cancer immunotherapy. This systematic review analyzes the AI’s impact on LNP engineering through machine learning-driven predictive models, generative adversarial networks (GANs) for novel lipid design, and neural network-enhanced biodistribution prediction. AI reduces the therapeutic development timeline through accelerated virtual screening of millions of lipid combinations, compared to conventional high-throughput screening. Furthermore, AI-optimized LNPs demonstrate improved tumor targeting. GAN-generated lipids show structural novelty while maintaining higher encapsulation efficiency; graph neural networks predict RNA-LNP binding affinity with high accuracy vs. experimental data; digital twins reduce lyophilization optimization from years to months; and federated learning models enable multi-institutional data sharing. We propose a framework to address key technical challenges: training data quality (min. 15,000 lipid structures), model interpretability (SHAP > 0.65), and regulatory compliance (21CFR Part 11). AI integration reduces manufacturing costs and makes personalized cancer vaccine affordable. Future directions need to prioritize quantum machine learning for stability prediction and edge computing for real-time formulation modifications. Full article