Wire Arc Additive Manufacturing (WAAM) represents a disruptive technology in the field of metal additive manufacturing. Understanding the relationship between input factors and layer geometry is crucial for studying the process comprehensively and developing various industrial applications such as slicing software and feedforward controllers. Statistical tools such as clustering and multivariate polynomial regression provide methods for exploring the influence of input factors on the final product. These tools facilitate application development by helping to establish interpretable models that engineers can use to grasp the underlying physical phenomena without resorting to complex physical models. In this study, an experimental campaign was conducted to print steel components using WAAM technology. Advanced statistical methods were employed for mathematical modeling of the process. The results obtained using linear regression, polynomial regression, and a neural network optimized using the Tree-structured Parzen Estimator (TPE) were compared. To enhance performance while maintaining the interpretability of regression models, clusterwise regression was introduced as an alternative modeling technique along with multivariate polynomial regression. The results showed that the proposed approach achieved results comparable to neural network modeling, with a Mean Absolute Error (MAE) of 0.25 mm for layer height and 0.68 mm for layer width compared to 0.23 mm and 0.69 mm with the neural network. Notably, this approach preserves the interpretability of the models; a further discussion on this topic is presented as well.

Anomaly detection is an important feature in modern additive manufacturing (AM) systems to ensure quality of the produced components. Although this topic is well discussed in the literature, current methods rely on black-box approaches, limiting our understanding of why anomalies occur, making complex the root cause identification and the consequent decision support about the action to take to mitigate them. This work addresses these limitations by proposing a structured workflow designed to enhance the explainability of anomaly detection models. Using the wire arc additive manufacturing (WAAM) process as a case study, we examined 14 wall structures printed with INVAR36 alloy under varying process parameters, producing both defect-free and defective parts. These parts were classified based on surface appearance and welding camera images. We collected welding current and voltage data at a 5 kHz sampling rate and extracted features from both time and frequency domains using a knowledge-based approach. Isolation Forest, k-Nearest Neighbor, Artificial Neural Network, XGBoost, and LGBM models were trained on these features, and the results shown best performance of boosting models, achieving F1 scores of 0.927 and 0.945, respectively. These models presented higher performance compared to other models like k-Nearest Neighbor, whereas Isolation Forest and Artificial Neural Network posses lower performance due to overfitting, with an F1 score of 0.507 and 0.56, respectively. Then, by leveraging the feature importance capabilities of these models, we identified key signal characteristics that distinguish between normal and anomalous behavior, improving the explainability of the detection process and in general about the process physics.

The methodology carried out in this work is based on non-parametric inference. The problem is framed as a regression analysis, and the solution is derived using the permutation approach. The proposed test does not rely on the assumption that the distribution of the response follows a specific family of probability laws, unlike other parametric approaches. This makes the test powerful, particularly when the typical assumptions of parametric approaches, such as the normality of data, are not satisfied and parametric tests are not reliable. Furthermore, this method is more flexible and robust with respect to parametric tests. A permutation test on the goodness-of-fit of a multiple regression model is applied. Hence, proposed solution consists of the application of permutation tests on the significance of the single coefficients and then a combined permutation test (CPT) to solve the overall goodness-of-fit testing problem. Furthermore, a Monte Carlo simulation study was performed to evaluate the power of the previously mentioned permutation approach, comparing it with the conventional parametric F-test for ANOVA and the bootstrap combined test, both commonly discussed in the literature on this statistical problem. Finally, the proposed non-parametric test was applied to real-world data to investigate the impact of age and smoking habits on medical insurance costs in the USA. The findings suggest that smoking and being at least 50 years old significantly contribute to increased medical insurance costs.

Technological innovation has significantly transformed the field of statistics, not only in data analysis but also in data collection. Traditional methods based on direct observation have evolved into hybrid approaches that combine passively collected data (e.g., from GPS or accelerometers) with active user input through digital interfaces. This evolution has led to Smart Surveys—next-generation tools that leverage smart devices, such as smartphones and wearables, to collect data actively (via questionnaires or images) and passively (via embedded sensors). Smart Surveys offer strategic value in industrial contexts by enabling real-time data collection on worker behavior, environments, and operational conditions. However, the heterogeneity of such data poses challenges in management, integration, and quality assurance. This study proposes a modular system architecture incorporating gamification elements to enhance user participation, particularly among hard-to-reach worker segments, such as mobile or shift workers. By leveraging motivational strategies and interactive feedback mechanisms, the system seeks to foster greater engagement while addressing critical data security and privacy concerns within industrial Internet of Things (IoT) environments.