Progress in inverse finite element method for aerospace structural health monitoring applications

This review critically examines recent progress in the inverse finite element method (iFEM) for aerospace structural health monitoring (SHM), consolidating developments and emerging interdisciplinary applications. It offers novel insights into the latest inverse formulations, supported by benchmark numerical comparisons that aid in selecting suitable formulations for efficient airframe prognosis. Recognizing the importance of full-field sensing in aerospace monitoring systems, this review presents a unified analysis of numerical and experimental validations while accounting for uncertainties inherent in real-world implementations. In addition to the shape-sensing applications of iFEM, this review further examines a comprehensive damage assessment framework, including methods for identifying damage topologies such as material discontinuities and degradation resulting from operational or environmental conditions. Interdisciplinary methodologies integrating iFEM with advanced modeling and data-driven frameworks are reviewed for their efficacy in real-time defect characterization, offering insights into their broader potential for aerospace digital twin (DT) implementations. In addition, this study identifies current limitations in iFEM and outlines future directions to enhance its robustness, scalability, and adaptability for the rapidly evolving aerospace sector. By reviewing emerging trends in iFEM, this article serves as a foundational reference for researchers and practitioners aiming to design efficient and cost-effective aerospace SHM solutions.