Boundary Measurements Reveal Hidden Defects in Molded Objects

Small defects trapped inside cast pieces during the mold filling process can compromise the strength of the finished object, and a new study addresses how to find them without cutting the material open. The research, published in Boundary Value Problems, tackles the inverse problem of identifying the locations of these flaws using only boundary measurements.

The work, authored by Mohamed Abdelwahed, Nejmeddine Chorfi and Henda Ouertani, was published on 7 October 2026 as an open access article. The authors note that the mold filling process can create small defects that become trapped within the material, weakening the cast piece.

To locate these flaws, the team developed a numerical algorithm based on the topological gradient optimization method.

The study is presented as a numerical method, meaning the reported contribution is the algorithm itself rather than clinical or industrial trial results. The article is currently shared as an accepted manuscript, citable with a permanent DOI, and is subject to further edits before the final Version of Record replaces it.

By framing defect detection as an inverse problem, the research connects mold quality control with established mathematical techniques for reconstructing internal features from external data. The authors state that their topological gradient based algorithm is designed to identify the locations of these trapped flaws, offering a computational route to assessing the integrity of three-dimensional molded objects from boundary information alone.

Subject of Research: Inverse problem methods for identifying small defects in three-dimensional molded objects from boundary measurements

Article Title: Identification of small defects in three-dimensional molded objects

Article References: Abdelwahed, M., Chorfi, N., & Ouertani, H. (2026). Identification of small defects in three-dimensional molded objects. Boundary Value Problems. https://doi.org/10.1186/s13661-026-02375-w

Image Credits: AI Generated

DOI: 10.1186/s13661-026-02375-w

Keywords: inverse problems, topological gradient, defect detection, mold filling, boundary measurements, numerical algorithm, cast pieces, Boundary Value Problems, optimization, material strength, Identification, small