Current approaches to digital twins in additive manufacturing: a systematic literature review
Leonard Tudorache, Önder Babur, Sandra S. Lucas, Mark van den Brand
Abstract
Abstract Digital twin (DT) technology has become a promising approach for improving the efficiency, quality, and reliability of manufacturing processes. This systematic literature review aims to conduct an in-depth analysis of the current approaches used to develop DTs for Additive Manufacturing (AM) process from January 2010 to May 2024. We analyzed 65 studies to identify the types of printers used, challenges and opportunities, methodologies, implementation approach, quality assurance, process optimization, integration of material behavior, and structural analysis. The results outline the challenges associated with data collection and processing due to real-time requirements or generating relevant data through sensors. Additionally, there is a need for accurate material behavior and structural analysis models to achieve efficient simulation modules, yet there has been limited research on integrating those. Standard engineering tools used for DTs in the literature are not employed in the AM context. Many studies present generic implementations for DTs that do not address the required level of detail to achieve an effective DT solution. Future work should focus on understanding the complex additive manufacturing process to build integrated and enhanced simulation capabilities of the DT and on employing standard engineering methodologies and tools for developing DTs in the context of AM.