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At least 343 records · Page 19
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Group structure selection with random forests

Choosing an appropriate group structure for multigroup transport is far from an exact science. For some applications, one blindly uses a group structure developed years ago by forgotten methods. Furthermore, one sometimes uses the same group structure for a variety of problems, even if the group structure was originally developed with a certain application in mind. In this work, we create optimized group structures with simulated annealing for critical assembly test problems and apply a random forest regressor with bagging to choose the best group structure based on parameters of the different test problems. The optimized group structures were generated using a simulated annealing optimizer for several simple, spherical, and unreflected problems. The optimization was performed to minimize a cost function that included fission rate, absorption rate, leakage, and k{sub eff}. A random forest regressor was then trained on a set of International Criticality Safety Benchmark Evaluation Project inputs and used to select one of these six group structures. The trained machine learning model chose the best group structure 65% of the time, and one of the three best 89% of the time. Furthermore, it decreased the L2 error over all test problems by a factor of 25 when compared to the standard Los Alamos 70-group structure. In other words, the model chose group structure that were far more appropriate for the test problems than the traditional LANL group structure. (authors)

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2023

Machine Learning Benchmarks for the Classification of Equivalent Circuit Models from Electrochemical Impedance Spectra

Analysis of Electrochemical Impedance Spectroscopy (EIS) data for electrochemical systems often consists of defining an Equivalent Circuit Model (ECM) using expert knowledge and then optimizing the model parameters to deconvolute various resistance, capacitive, inductive, or diffusion responses. For small data sets, this procedure can be conducted manually; however, it is not feasible to manually define a proper ECM for extensive data sets with a wide range of EIS responses. Automatic identification of an ECM would substantially accelerate the analysis of large sets of EIS data. We showcase machine learning methods to classify the ECMs of 9,300 impedance spectra provided by QuantumScape for the BatteryDEV hackathon. The best-performing approach is a gradient-boosted tree model utilizing a library to automatically generate features, followed by a random forest model using the raw spectral data. A convolutional neural network using boolean images of Nyquist representations is presented as an alternative, although it achieves a lower accuracy. We publish the data and open source the associated code. The approaches described in this article can serve as benchmarks for further studies. A key remaining challenge is the identifiability of the labels, underlined by the model performances and the comparison of misclassified spectra.

25 ENERGY STORAGE↗
DOE OSTI2024

Machine learning approaches for influenza A virus risk assessment identifies predictive correlates using ferret model in vivo data

In vivo assessments of influenza A virus (IAV) pathogenicity and transmissibility in ferrets represent a crucial component of many pandemic risk assessment rubrics, but few systematic efforts to identify which data from in vivo experimentation are most useful for predicting pathogenesis and transmission outcomes have been conducted. To this aim, we aggregated viral and molecular data from 125 contemporary IAV (H1, H2, H3, H5, H7, and H9 subtypes) evaluated in ferrets under a consistent protocol. Three overarching predictive classification outcomes (lethality, morbidity, transmissibility) were constructed using machine learning (ML) techniques, employing datasets emphasizing virological and clinical parameters from inoculated ferrets, limited to viral sequence-based information, or combining both data types. Among 11 different ML algorithms tested and assessed, gradient boosting machines and random forest algorithms yielded the highest performance, with models for lethality and transmission consistently better performing than models predicting morbidity. Comparisons of feature selection among models was performed, and highest performing models were validated with results from external risk assessment studies. Our findings show that ML algorithms can be used to summarize complex in vivo experimental work into succinct summaries that inform and enhance risk assessment criteria for pandemic preparedness that take in vivo data into account.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2024

Insights into Prismatic Loop Formation in Irradiated Fe–Cr Alloys from Hypothesis-Driven Active Learning and Causal Analysis

Neutron and electron irradiation experimental studies conducted on body-centered cubic Fe and Fe–Cr alloys have established two prismatic dislocation loop populations, which have Burgers vectors of either a/2$\langle$111$\rangle$ or a$\langle$100$\rangle$. Here, the loop formation depends on factors such as dose (D), dose rate (D rt ), temperature (T), chromium content (Cr%), and other alloying elements. Hence, it is important to understand how irradiation-induced dislocation loops evolve conditional upon the loop characteristics, such as loop density (DD), average loop size d̅, and irradiation parameters (D, D rt , T, and irradiation type), which is still an active area of research. To understand these complex structure–property relationships, machine learning (ML) is employed in a three-step approach. This includes imputing missing data with a k-nearest neighbor, generating functionalized features, and assessing feature importance with random forest classification and regression. Physics-based features are incorporated in a hypothesis-driven active learning scheme to overcome data unavailability challenges. Insights obtained from ML models (i) to categorize dislocation loop types, show the highest correlation with d̅; (ii) Log(DD), obtained through mathematical formulations involving D, Cr%, d̅, and T (e.g., Log(DD) ~ D + exp(-Cr%) + 1/d̅ and log(DD) ~ D + exp(-Cr%) + 1/T). Hypothesis-driven active learning is able to predict Log(DD) in which the experimental date is not known. Causal models verify cause–effect relationships for dislocation loop classification and irradiation factors in FeCr alloys.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2024

Upscaling Soil Organic Carbon Measurements at the Continental Scale Using Multivariate Clustering Analysis and Machine Learning

Abstract Estimates of soil organic carbon (SOC) stocks are essential for many environmental applications. However, significant inconsistencies exist in SOC stock estimates for the U.S. across current SOC maps. We propose a framework that combines unsupervised multivariate geographic clustering (MGC) and supervised Random Forests regression, improving SOC maps by capturing heterogeneous relationships with SOC drivers. We first used MGC to divide the U.S. into 20 SOC regions based on the similarity of covariates (soil biogeochemical, bioclimatic, biological, and physiographic variables). Subsequently, separate Random Forests models were trained for each SOC region, utilizing environmental covariates and SOC observations. Our estimated SOC stocks for the U.S. (52.6 ± 3.2 Pg for 0–30 cm and 108.3 ± 8.2 Pg for 0–100 cm depth) were within the range estimated by existing products like Harmonized World Soil Database, HWSD (46.7 Pg for 0–30 cm and 90.7 Pg for 0–100 cm depth) and SoilGrids 2.0 (45.7 Pg for 0–30 cm and 133.0 Pg for 0–100 cm depth). However, independent validation with soil profile data from the National Ecological Observatory Network showed that our approach ( R 2 = 0.51) outperformed the estimates obtained from Harmonized World Soil Database ( R 2 = 0.23) and SoilGrids 2.0 ( R 2 = 0.39) for the topsoil (0–30 cm). Uncertainty analysis (e.g., low representativeness and high coefficients of variation) identified regions requiring more measurements, such as Alaska and the deserts of the U.S. Southwest. Our approach effectively captures the heterogeneous relationships between widely available predictors and the current SOC baseline across regions, offering reliable SOC estimates at 1 km resolution for benchmarking Earth system models.

58 GEOSCIENCES↗
DOE OSTI2021

Utilizing physics-based input features within a machine learning model to predict wind speed forecasting error

Machine learning is quickly becoming a commonly used technique for wind speed and power forecasting. Many machine learning methods utilize exogenous variables as input features, but there remains the question of which atmospheric variables are most beneficial for forecasting, especially in handling non-linearities that lead to forecasting error. This question is addressed via creation of a hybrid model that utilizes an autoregressive integrated moving-average (ARIMA) model to make an initial wind speed forecast followed by a random forest model that attempts to predict the ARIMA forecasting error using knowledge of exogenous atmospheric variables. Variables conveying information about atmospheric stability and turbulence as well as inertial forcing are found to be useful in dealing with non-linear error prediction. Streamwise wind speed, time of day, turbulence intensity, turbulent heat flux, vertical velocity, and wind direction are found to be particularly useful when used in unison for hourly and 3 h timescales. The prediction accuracy of the developed ARIMA–random forest hybrid model is compared to that of the persistence and bias-corrected ARIMA models. The ARIMA–random forest model is shown to improve upon the latter commonly employed modeling methods, reducing hourly forecasting error by up to 5 % below that of the bias-corrected ARIMA model and achieving an R 2 value of 0.84 with true wind speed.

17 WIND ENERGY↗
DOE OSTI2024

Advanced Data Science Model for Detecting Intelligent Malware

This study focused on developing a robust artificial intelligence (AI) model capable of detecting and characterizing advanced malware in Internet of Things (IoT) devices using network data. By analyzing network traffic with various machine learning (ML) models, our AI model can identify and characterize malicious activities to significantly improve malware detection accuracy and reliability as compared to traditional methods. The developed AI/ML model was trained using network data from IoT devices, leveraging classifiers such as Random Forest, Gradient Boosting, AdaBoost, and others to optimize detection performance. This project demonstrates a scalable framework for real-time malware detection and characterization in IoT networks, capable of identifying infected devices and facilitating the necessary steps to remove or isolate them, thereby preventing further infections. Although digital twin (DT) integration is not yet implemented in the current model, it represents a promising future enhancement. By creating a virtual replica of physical IoT devices, DT technology would allow for real-time monitoring and analysis without directly accessing operational technology, thus reducing the risk of compromising or reducing the performance of actual devices. This integration would further enhance the security of IoT ecosystems, combining AI technology to better flag and detect indications of malware-infected devices within a nuclear system environment.

42 ENGINEERING↗
DOE OSTI2023

A review on recent machine learning applications for imaging mass spectrometry studies

Imaging mass spectrometry (IMS) is a powerful analytical technique widely used in biology, chemistry, and materials science fields that continue to expand. IMS provides a qualitative compositional analysis and spatial mapping with high chemical specificity. The spatial mapping information can be 2D or 3D depending on the analysis technique employed. Due to the combination of complex mass spectra coupled with spatial information, large high-dimensional datasets (hyperspectral) are often produced. Therefore, the use of automated computational methods for an exploratory analysis is highly beneficial. The fast-paced development of artificial intelligence (AI) and machine learning (ML) tools has received significant attention in recent years. These tools, in principle, can enable the unification of data collection and analysis into a single pipeline to make sampling and analysis decisions on the go. There are various ML approaches that have been applied to IMS data over the last decade. Here, in this review, we discuss recent examples of the common unsupervised (principal component analysis, non-negative matrix factorization, k-means clustering, uniform manifold approximation and projection), supervised (random forest, logistic regression, XGboost, support vector machine), and other methods applied to various IMS datasets in the past five years. The information from this review will be useful for specialists from both IMS and ML fields since it summarizes current and representative studies of computational ML-based exploratory methods for IMS.

47 OTHER INSTRUMENTATION↗
DOE OSTI2026

The Role of Nuclear Data Sensitivities in Prompt α-Eigenvalue Predictions of Delayed Critical Benchmarks

Alpha (α) eigenvalues, which describe the logarithmic time derivative of the neutron population in a multiplying system, are integral to time-dependent behavior and diagnostic applications. However, uncertainties in the evaluated nuclear data can significantly impact the accuracy of transport simulations for such quantities. This work explores the use of machine learning models to predict two key outputs, α-eigenvalues and keff bias, using input features derived from α-eigenvalue sensitivities to nuclear data. The criticality safety benchmark models used in this study come from the International Handbook of Evaluated Criticality Safety Benchmark Experiments. Three models, random forest, XGBoost, and NGBoost, are trained on both energy-resolved and energy-summed α sensitivities. For the α-eigenvalue bias prediction, NGBoost achieved the highest R 2 (0.9476) using energy-resolved features, while XGBoost performed best using summed sensitivities. In contrast, when predicting the keff bias, all the models showed moderate predictive capability (best R 2 ≈ 0.72), as the mapping from the static α-sensitivities to the static keff bias was less direct. SHAP (SHapley Additive exPlanations) analysis was used to interpret the model predictions. Across both prediction tasks, the features associated with neutron capture [H-1 (n, γ)], uranium scattering reactions (such as 235 U elastic/inelastic), and actinide capture/fission reactions (such as 239 Pu and 234 U) were consistently identified as the most impactful. This highlights the key role of specific nuclear reactions and energy ranges in shaping both time-dependent and steady-state criticality behavior. These results demonstrated that α-sensitivities, despite being computed for time-dependent metrics, can provide valuable insights for predicting both α-eigenvalues and the keff bias. Moreover, machine learning models offer a promising pathway for uncovering important nuclear data dependencies and guiding future data evaluation efforts.

Nuclear data↗
DOE OSTI2023

First estimation of high-resolution solar photovoltaic resource maps over China with Fengyun-4A satellite and machine learning

Fengyun-4A (FY-4A), which is the latest-generation Chinese geostationary meteorological satellite, measures solar reflection and thermal emission with high temporal, spatial, and spectral resolutions. It is expected to be highly beneficial for solar resource assessment and forecasting in China. This study is the first to estimate, using FY-4A and a random forest model, the global horizontal irradiance (GHI) at a 4-km–15-min spatio-temporal resolution over China, as a means to arrive at a solar photovoltaic (PV) resource map. In terms of GHI estimates, the root mean square error and mean bias error between hourly measured and retrieved values are 147.02 (35.2%), –5.64 W/m 2 (–1.4%), respectively, whereas the values of daily estimates are 29.20 (18.0%), –2.97 W/m 2 (–1.3%). The retrieval accuracy is found much better for instances with solar zenith angles smaller than 60°. Relatively larger errors are found at locations in the Sichuan Basin and northeastern China, which can be attributed to bright surfaces and/or strong cloud transients. With the retrieved irradiance, PV resource is derived through a physical model chain. The annual mean PV resource map suggests that, over most of the west areas, the annual mean effective irradiance exceeds 1700 kWh/m 2 , with the highest value found in Tibet (around 2000 kWh/m 2 per annum). Eastern China has an annual effective irradiance of only 1300–1500 kWh/m 2 . In conclusion, the region with poorest solar resource is the Sichuan Basin (less than 1100 kWh/m 2 per annum).

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2022

SourceFinder: a Machine-Learning-Based Tool for Identification of Chromosomal, Plasmid, and Bacteriophage Sequences from Assemblies

High-throughput genome sequencing technologies enable the investigation of complex genetic interactions, including the horizontal gene transfer of plasmids and bacteriophages. However, identifying these elements from assembled reads remains challenging due to genome sequence plasticity and the difficulty in assembling complete sequences. In this study, we developed a classifier, using random forest, to identify whether sequences originated from bacterial chromosomes, plasmids, or bacteriophages. The classifier was trained on a diverse collection of 23,211 chromosomal, plasmid, and bacteriophage sequences from hundreds of bacterial species. In order to adapt the classifier to incomplete sequences, each complete sequence was subsampled into 5,000 nucleotide fragments and further subdivided into k-mers. This three-class classifier succeeded in identifying chromosomes, plasmids, and bacteriophages using k-mer distributions of complete and partial genome sequences, including simulated metagenomic scaffolds with minimum performance of 0.939 area under the receiver operating characteristic curve (AUC). This classifier, implemented as SourceFinder, has been made available as an online web service to help the community with predicting the chromosomal, plasmid, and bacteriophage sources of assembled bacterial sequence data (https://cge.food.dtu.dk/services/SourceFinder/).

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2024

Snow Distribution Patterns Revisited: A Physics-Based and Machine Learning Hybrid Approach to Snow Distribution Mapping in the Sub-Arctic

Snowpack distribution in Arctic and alpine landscapes often occurs in repeating, year-to-year patterns due to local topographic, weather, and vegetation characteristics. Previous studies have suggested that with years of observational data, these snow distribution patterns can be statistically integrated into a snow process modeling workflow. Recent advances in snow hydrology and machine learning (ML) have increased our ability to predict snowpack distribution using in-situ observations, remote sensing data sets, and simple landscape characteristics that can be easily obtained for most environments. Here, we propose a hybrid approach to couple a ML snow distribution pattern (MLSDP) map with a physics-based, snow process model. We trained a random forest ML algorithm on tens of thousands of snow survey observations from a subarctic study area on the Seward Peninsula, Alaska, collected during peak snow water equivalent (SWE). We validated hybrid model outputs using in-situ snow depth and SWE observations, as well as a light detection and ranging data set and a distributed temperature profiling sensor data set. When the hybrid results were compared with the physics-based method, the hybrid method more accurately depicted the spatial patterns of the snowpack, areas of drifting snow, and years when no in-situ observations were used in the random forest ML training data set. The hybrid method also showed improvements in root mean squared error at 61% of locations where time-series estimations of snow depth were observed. These results can be applied to any physics-based model to improve the snow distribution patterning to reflect observed conditions in high latitude and high elevation cold region environments.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2026

Statistical and Machine Learning Approaches to Analyzing Pipeline Incidents in the United States (2010–2024)

This study applies machine learning methods to analyze natural gas pipeline incidents in the United States using the Pipeline and Hazardous Materials Safety Administration (PHMSA) Gas Distribution Incident Dataset (2010–2024). The dataset includes over 600 variables describing incident characteristics, infrastructure attributes, and contributing factors associated with unintentional gas releases. The objective is to assess whether these features can reliably predict the underlying cause of pipeline failures. Multinomial logistic regression and Random Forest models were developed to classify incident causes, including excavation damage, corrosion, equipment failure, and natural forces. Results show that excavation damage is both the most frequent and most predictable cause, with models achieving strong performance for this category. However, when excavation damage is excluded, model accuracy declines significantly, with some models performing near random levels. Across all approaches, severe class imbalance and limited variability in key predictors constrain predictive performance. Pipeline age and diameter emerge as the most influential variables, but they provide insufficient discriminatory power to distinguish among less frequent failure types. These findings indicate that non-excavation-related incidents are rare, heterogeneous, and weakly represented in the dataset, limiting the effectiveness of machine learning classification. Overall, this study highlights the structural limitations of the PHMSA dataset for predictive modeling and underscores the need for improved data balance and feature enrichment. The results reinforce excavation damage prevention as the most impactful strategy for reducing pipeline incidents.

03 NATURAL GAS↗
DOE OSTI2026

Machine learning for seismic low-frequency extrapolation

The cycle-skipping problem that plagues full waveform inversion (FWI) can be at least partially mitigated if low frequencies (which encode the kinematics of wave propagation in seismic data) are recorded. However, seismic sources and receivers are band-limited, so seismic data does not generally include signals down to 0 Hz. To improve our ability to solve the seismic inverse problem, one can synthesize this missing low-frequency (LF) content from the recorded high-frequency (HF) data using machine learning (ML) models. Deep learning models such as convolutional neural networks (CNNs) demonstrate impressive ability to perform low frequency extrapolation. However, such models require powerful hardware (GPU machines) and careful training. We assess the extrapolation capabilities of three different ML models that do not require GPU machines, namely, random forest, Gaussian process regression and gradient boosting, on both synthetic and real data. Experimental results on two synthetic data sets (generated from a low velocity lens embedded in a homogeneous medium, and the Marmousi model) demonstrate that FWI applied to the extrapolated data consistently improves inversion accuracy relative to FWI applied to the original data sets that do not contain low frequencies. Application of low-frequency extrapolation to real data from the Northwest Shelf of Australia demonstrates that tree-based ML models such as gradient boosting can outperform CNNs in terms of both accuracy and computational cost on non-GPU architectures.

58 GEOSCIENCES↗
DOE OSTI2025

Toward Drilling the Perfect Geothermal Well: An International Research Coordination Network for Geothermal Drilling Optimization Supported by Deep Machine Learning and Cloud Based Data Aggregation

The EDGE project, supported by the U.S. Department of Energy Geothermal Technologies Office under award DE-EE0008793, established a data-driven framework for improving the efficiency, cost-effectiveness, and reliability of geothermal well drilling. The project focused on developing scalable data infrastructure, advanced machine learning and probabilistic models, and integrated analytics tools to support continuous drilling optimization. A central objective was to reduce geothermal drilling costs by up to seventy percent while minimizing the risk of well failure through predictive diagnostics and adaptive planning. Over the project period, a comprehensive data repository was designed and deployed, incorporating records from over one hundred geothermal wells across varied geological settings. This repository supported both structured and unstructured data and adhered to FAIR data principles, enabling provenance tracking, quality control, and standardized metadata. The project introduced automated ingestion pipelines and a cloud-hosted platform that facilitated access to raw, processed, and derived datasets. This infrastructure served as the foundation for model development and analysis. Machine learning workflows were developed to predict key drilling metrics including rate of penetration, non-productive time, and total drilling costs. Self-organizing maps and dimensionality reduction methods were used to uncover operational patterns and outliers, while supervised learning algorithms such as random forests and deep neural networks were applied to forecast performance outcomes. The models were validated on heterogeneous datasets from both U.S. and Icelandic fields, demonstrating variable but significant predictive accuracy. The results indicated that finer temporal resolution, inclusion of lithological data, and consistency in operational annotations could substantially improve model performance. The project also implemented process mining techniques to reconstruct state-transition models from drilling event logs. These models enabled the identification of deviations from optimal workflows and provided insights into recurring failure modes. Analysis of non-productive time highlighted the impact of equipment failures, geological challenges, and human factors, offering opportunities for targeted mitigation strategies. The EDGE Dashboard was developed as a web-based expert system integrating data visualization, model outputs, and user-driven queries. It provided an accessible interface for operators to explore historical data, evaluate predicted outcomes, and compare drilling scenarios. Initial feedback from project partners suggested that the dashboard could serve as a foundation for more advanced advisory and optimization tools. Overall, the EDGE project demonstrated the feasibility and value of applying modern data science techniques to geothermal drilling. It delivered a set of interoperable tools and models that can support more efficient, lower-risk well development. The findings point toward a viable path for transitioning from advisory analytics to semi-autonomous drilling systems, contingent on continued collaboration, expanded datasets, and field validation. The project results have immediate relevance for drilling operations, data management practices, and future geothermal R&D efforts aimed at achieving reliable, cost-competitive geothermal energy at scale.

15 GEOTHERMAL ENERGY↗
DOE OSTI2025

Machine learning and process-based modeling of spatiotemporal changes in active layer thickness across Alaska

Permafrost degradation poses a growing threat to infrastructure stability and ecosystem resilience in the rapidly warming Arctic. We investigated the spatiotemporal dynamics of active layer thickness (ALT) across Alaska by integrating field observations, environmental datasets, a physically based Stefan model, and machine learning (ML) techniques. Using weather projections from the Coupled Model Intercomparison Project Phase 6 under two Shared Socioeconomic Pathways (SSP 2-4.5 and SSP 5-8.5), we assessed ALT sensitivity to projected future weather conditions. The random forest (RF) model outperformed the Stefan approach in predicting ALT on the training dataset (R² = 0.84 vs. 0.53) but demonstrated lower generalizability on the test dataset (R² = 0.24 vs. 0.54). The root mean square error (RMSE) for the RF model for training and testing ranged from 14 to 22 cm, compared to 17 and 18 cm for the Stefan model. Variable importance analysis revealed that mean annual temperature and slope angle were the strongest predictors of ALT, accounting for 19% and 18% of the variance, respectively, followed by sediment transport index (14%) and stream power index (11%). Comparative analysis of baseline ALT predictions showed the Stefan model tended to project a thicker active layer (mean ± SD: 65 ± 16 cm), compared to the RF model (mean ± SD: 59 ± 8.8) cm). Both models indicated a latitudinal gradient in ALT, with shallower depths at higher latitudes. Projected ALT increases by 2100 were estimated at 3.3 ± 2.2 cm under SSP 2-4.5 and 5.9 ± 4.0 cm under SSP 5-8.5 for the ML model, whereas the Stefan model projected substantially larger increases of 13 ± 2.6 cm (SSP 2-4.5) and 28 ± 4.4 cm (SSP5-8.5). Spatial analysis showed the greatest ALT increases in northern Alaska, with relatively smaller changes in southern regions. These findings highlight the complex, multifactorial nature of ALT dynamics and the value of hybrid modeling approaches. As rising temperatures accelerate permafrost thaw, changes in ALT can disrupt ecosystems, damage infrastructures, and enhance the release of stored soil carbon, highlighting the urgent need for improved predictive capabilities to inform adaptation strategies in the Arctic.

Climate sciences↗
DOE OSTI2021

Geometrical defect detection for additive manufacturing with machine learning models

This study proposed a scheme based on Machine Learning (ML) models to detect geometric defects of additively manufactured objects. The ML models are trained with synthetic 3D point clouds with defects and then applied to detect defects in actual production. Using synthetic 3D point clouds rather than experimental data could save a huge amount of training time and costs associated with many prints for each design. Besides distance differences of individual points between source and target point clouds, this scheme uses a new concept called “patch” to capture macro-level information about nearby points for ML training and implementation. Numerical comparisons of prediction results on experimental data with different shapes showed that the proposed scheme outperformed the existing Z-difference method in the literature. Five ML methods (Bagging of Trees, Gradient Boosting, Random Forest, K-nearest Neighbors and Linear Supported Vector Machine) were compared under various conditions, such as different point cloud densities and defect sizes. Bagging and Random Forest were found the two best models regarding predictability; and the right patch size was found to be at 20. The proposed ML-based scheme is applicable to in-situ defect detection during additive manufacturing with the aid of a proper 3D data acquisition system.

Additive manufacturing↗