GenVoid: Uncertainty-Aware Learning of Subsurface Material Defects with an Experimentally Validated Physics-Informed Generative Model

Internal voids are ubiquitous defects in manufactured structures, yet their characterization remains challenging because their geometry is hidden and can only be inferred indirectly from accessible measurements. Here we introduce textitGenVoid, a physics-informed generative model-based framework for identifying internal voids in complex two- and three-dimensional solids from surface displacement measurements alone. By incorporating the governing mechanics into a generative inference framework, textitGenVoid enables void identification across linear elastic, hyperelastic and plastic material behaviours and accommodates complex two- and three-dimensional structural geometries. Importantly, the framework explicitly accounts for uncertainty and noise in displacement measurements, producing probabilistic reconstructions of internal void geometry rather than a single deterministic estimate. We demonstrate the approach using high-fidelity synthetic datasets and experimentally measured displacement fields obtained from in-situ mechanical experiments, establishing its ability to infer hidden voids from realistic displacement measurements. To quantify the fundamental limits of such inference, we further introduce an observability measure that characterizes the sensitivity of boundary measurements to localized stiffness perturbations within the interior under an ensemble of applied loads. This framework provides a direct connection between defect location, sensor configuration and reconstruction fidelity, enabling systematic assessment of how the number and spatial distribution of boundary measurements govern void-identification accuracy. To this end, these results establish a physics-informed and uncertainty-aware approach for non-invasive characterization of hidden defects and provide a quantitative basis for designing measurement strategies for inverse problems in solid mechanics.