Hybrid Physical–Virtual Digital Twin System for Additive Manufacturing

This study presents a hybrid physical–virtual digital twin system to enhance additive manufacturing (AM). The system aims to achieve real-time monitoring, predictive modeling, and improved 3D printing control. It integrates sensing-driven and simulation-driven digital twins into a comprehensive hybrid digital twin environment (HDTE) tailored for the Creality Ender-5 Plus 3D printer within the Unity 3D virtual environment. The AM process simulation employs a three-dimensional transient finite element model, enabling precise predictions of thermodynamics, residual stress, final distortion, and solidification parameters. To enhance real-time insights, external sensors like thermocouples, thermal cameras, and LIDAR ranging sensors continuously collect temperature and location data during 3D printing. Experimental results confirm the HDTE’s accuracy. Position assessment experiments show their ability to replicate component positions under varying conditions, while temperature assessment experiments demonstrate their capacity to mimic temperature variations promptly and accurately. The study also provides a detailed analysis of nodal temperature distribution within a 3D printed plate, indicating potential for predictive defect detection and print parameter optimization. Additionally, the study integrates a closed-loop control mechanism, ensuring rigorous quality control, although a detailed exposition of this system is reserved for future publications. This paper bridges the gap between virtual design and physical AM production, offering real-time monitoring, predictive capabilities, and automated control. These advancements enhance efficiency, reduce material waste, and promote sustainability. As this system evolves, it promises to revolutionize additive manufacturing, ushering in a data-driven era of intelligent 3D printing across industries.