Physics-informed 3D deformation tracking for dimensional accuracy control of manufactured components

Dimensional accuracy is essential in advanced manufacturing, yet geometry distortion is always inevitable irrespective of parameter optimisation. Here, inspired by computer graphics, we propose a physics-informed 3D deformation tracking method following the principles of continuum mechanics. The displacement and strain fields for each 3D volume element of a design are calculated from the measured point clouds of a fabricated model to establish accurate material point correspondence, providing a base for geometrical compensation to counterbalance distortion. As a case study, qualified investment castings of femoral condyle implants with fine geometries and micron-level dimensional accuracy were fabricated via a single trial-production. Our findings demonstrate the theoretical feasibility of precisely tracking real complex physical deformation, providing a broad and efficient data-driven approach for manufacturing key complex components with high precision.