Design and Implementation of a Digital Twin-Based Virtual Material Simulation System

This paper presents the design and implementation of a digital twin-based virtual material simulation system that seamlessly bridges real-world experimentation and virtual simulation, enabling researchers to visualize, analyze, and reproduce material behaviors across both domains. The proposed system supports two operational modes to accommodate diverse experimental scenarios: real-time mode and simulation mode. In real-time mode, sensor data collected from physical experiments, such as those conducted in environmental facilities or testbeds, are transmitted through a middleware layer to a digital twin, where the experimental environment and material responses are visualized instantaneously. In simulation mode, historical experimental data stored in the data platform are replayed to perform virtual experiments and explore conditions that are physically infeasible. Both modes are realized through an integrated architecture connecting physical experiment devices, middleware-based data mediation, and a service layer that provides visualization and control via a digital twin and web portal. Implementation results confirm successful synchronization between physical and virtual experiments, including real-time data ingestion, simulation replay, and control feedback. The proposed system enhances experimental reproducibility, automation, and remote operation, contributing to data-driven research and intelligent optimization in digital twin environments. In addition, the proposed system incorporates quantitative evaluation pipelines that measure simulation accuracy, end-to-end latency, and real-time synchronization fidelity, demonstrating that the integrated digital twin environment operates with high technical reliability.