A model-based deep learning framework for damage classification and detection in polycarbonate infused with AEROSIL under dynamic loading conditions

Composite 3D printing is a significant engineering application owing to its robustness, ability to achieve complex geometries, and ease of use. Polycarbonate, particularly when infused with AEROSIL, is an interesting thermoplastic and potential candidate for 3D printing with enhanced properties. The primary objective of this research is to develop a new model-based deep-learning framework to classify and detect damage in this material under dynamic loading conditions. To achieve this, a FASTCAM high-speed camera was placed in front of the SHPB test setup to capture dynamic damage. The test results were then used as label inputs for training the advanced deep learning algorithms, focusing on dense image recognition techniques for detailed damage analysis. The study involved a series of fully convolutional networks (FCNs), evaluating semantic segmentation with U-Net and instance segmentation with state-of-the-art frameworks such as YOLOv8 and Mask R–CNN. A comparative analysis revealed that deep learning models outperform traditional methods, providing efficient and accurate damage classification and detection. The U-Net model demonstrated the ability to recognize cubes and bars but was limited in detecting minor damage regardless of size. YOLO-V8, which specializes in case segmentation, achieved remarkable performance in detecting significant damage but struggled to accurately identify minor damage. By leveraging deep learning techniques, this study enables an efficient and accurate damage assessment, which is crucial for ensuring the reliability and safety of composite structures in various industries.