Mechanics-AI: A Bio-Inspired Physics Intelligence Pipeline for Cross-Domain Engineering Prediction and Sustainable Design

Mechanistic simulation and machine learning are powerful but complementary tools: physics-based simulation is interpretable yet computationally expensive and blind to real-world context, whereas machine learning is fast but data-hungry and opaque. Biological systems resolve this tension elegantly, coupling physically grounded mechanoreceptor sensing with higher-level neural interpretation that places those signals in context. Inspired by this layered architecture, we present Mechanics-AI, an open-source framework that mirrors the same sensing-then-interpretation logic computationally. A first learning layer (ML1) emulates expensive finite-element, computational fluid dynamics and multiphysics simulations to produce interpretable physical metrics such as stress, strain, shear, and thermal and moisture fields, while a second layer (ML2) fuses these metrics with heterogeneous real-world metadata to predict categorical outcomes and design recommendations. Eight algorithms are benchmarked automatically, the most accurate is selected for each task, and Shapley additive explanations expose the dominant physical drivers to preserve interpretability. The framework is demonstrated across three independent domains using a single unchanged pipeline: forensic traumatic brain injury prediction, optimisation of a bio-inspired humanoid bioreactor for tissue engineering, and a zero-emission building (ZEBAI) framework that couples thermo-hygro-mechanical simulation with Sobol-sampled surrogate modelling to design sustainable, low-carbon envelopes from recycled aggregate concrete by balancing structural safety, energy and embodied carbon. Despite entirely different physics, data and objectives, the same architecture generalises across all three, showing that bio-inspired, layered coupling of mechanistic simulation and contextual learning offers a reusable, interpretable route to cross-domain engineering prediction and sustainable design.