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NASA NTRSDate not supplied

Digital Twins and Living Models at NASA

The idea of a “digital twin” was born at NASA in the 1960s as a “living model” of the Apollo mission. In response to Apollo 13’s oxygen tank explosion and subsequent damage to the main engine, NASA employed multiple simulators to evaluate the failure and extended a physical model of the vehicle to include digital components. This “digital twin” was the first of its kind, allowing for a continuous ingestion of data to model the events leading to up to the accident for forensic analysis and exploration of next steps. Fast forward half a century and NASA, along with others in the aerospace community, continues to develop and utilize high-fidelity digital models of physical systems and components as well as the extreme environments in which they operate. NASA aims to travel further and stay longer in space as we realize the Artemis program, taking us from the moon to Mars by establishing a sustainable presence on the Moon to prepare for missions to Mars. We will no longer be able to rely on constant connectivity with an asset nor be in-the-loop for on-demand human intervention in the event of an anomaly. Further, the importance of digital twins is increasing as we seek alternatives for certification of structures so large that they cannot be fully evaluated in existing test facilities and autonomous systems that are not deterministic. The idea of a digital twin is not a new one. What is new is the scale, ordinality, and non-deterministic nature of the models that are critical to achieving NASA’s goals. Their number and autonomy from each other as well as the reference system is suggestive of a changing ecosystem, returning us the idea of a living model.

Digital Twin↗

DOE OSTI2025

High Fidelity Digital Twins for BWRX-300 Critical Systems

This project developed and demonstrated digital-twin technology for advanced nuclear systems under the ARPA-E GEMINA program, with a focus on the BWRX-300 small modular reactor. The primary objective was to reduce operation and maintenance (O&M) costs through predictive health monitoring and model-based fault detection. The project combined MIT’s high-fidelity physics models and machine-learning and digital-twin algorithms, and GE Hitachi’s digital-twin algorithms and operational expertise to build physics-based digital twins capable of real-time system monitoring and maintenance scheduling.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2025

First-of-a-Kind Risk-Informed Digital Twin for Operational Decision Making

A digital twin (DT) is a digital model or a collection of models of a physical entity. DTs in the nuclear arena can be used from plant design through decommissioning. Decisions are typically a priori or made offline. Risk-informed decision making is identifying what can go wrong, its frequency, and the consequences of its failure. Ideally risk-informed decision making reflects the current state of the plant and provides a decision in real time. Traditionally, probabilistic risk assessments (PRAs) evaluate the failures of safety systems, the risk of core damage, and the offsite dose as the consequence. However, this DT evaluates the decisions on the control side rather than the protection side. It uses the same risk methods to probabilistically inform the decision-making process but in a different way. Rather than evaluating the risk of core damage, this DT evaluates the likelihood of avoiding a trip set point while maintaining plant safety. Performance-based assessments are identified via its probabilistic evaluation of operational alternatives based on system status. Because the purpose of the control system is to maintain system variables within prescribed operating ranges, upsets or challenges that can exceed a trip set point resulting in a plant transient and a challenge to plant mitigating systems based on actual plant conditions, are evaluated to safely maintain the plant within the operating ranges. The probabilistic portion of the model is autonomously and automatically adjusted, and the metric of interest (i.e. likelihood of avoiding a trip set point) is recalculated. The digital representation of the physical system (i.e. the DT) performs a deterministic performance–based assessment of the probabilistically identified alternatives identified to validate the probabilistic assessment. A decision-making algorithm selects the appropriate option based on the probabilistic and deterministic assessments and transmits a control signal to a component(s) to initiate a corrective action or informs an operator of its decision.

digital twin↗

DOE OSTI2025

Establishing Models for Digital Twin of Hydropower Systems Using Probability Density Function Shaping

This paper introduces a digital twin modeling method for hydropower systems with Kaplan turbines using probability density function (PDF) shaping. We first use multilayer perceptron (MLP) model to build the discretized openloop Kaplan unit, where the MLP is trained by historical data. Then we use a proportional integral double derivative (PIDD) controller and a lead-lag exciter to test the obtained digital twin model in a closed-loop fashion. Simulation results show that the proposed digital twin modeling method can accurately capture the dynamics of the Kaplan hydropower unit. Finally, we show that the obtained digital twin can help to optimize the PIDD parameters. Compared with the original PIDD controller, the optimized one can achieve an over 90% improvement on the mean square tracking error.

Yin, Zhun [New York University]↗

DOE OSTI2025

Immersive Digital Twin Laboratory for Engineering Education (CRADA Final Report)

This project aimed to create an immersive digital twin laboratory that incorporates advanced tracking and visualization capabilities. In collaboration with Fort Lewis College, NREL designed a state-of-the-art physical visualization laboratory, developed a software platform to enable interaction with tracked physical objects in the laboratory, and provided proof-of-concept curricula that included manipulating these tracked objects. The project was initiated to address the growing need for innovative educational tools in engineering education. As renewable energy systems, particularly solar installations, become more complex, there is a pressing need to bridge the gap between theoretical knowledge and practical application. Traditional methods of teaching solar engineering concepts often fall short of providing students with a comprehensive, hands-on understanding. This immersive digital twin laboratory was conceived to fill that gap by creating a safe, non-energized setting where students can interact with augmented solar installation objects, gaining valuable insights into system performance, design, and maintenance. The project utilized extended reality (XR) technologies, including head-mounted displays (HMDs) and a whole-room optical motion tracking system, to connect physical objects with their digital twins in real time. The laboratory was equipped with MagicLeap 2 HMDs, supported by a Vicon Vero 2.2 Optical Tracking System, which provided precise 6-degrees-of-freedom (6-DOF) tracking. We developed a software platform to manage the interaction between the tracked physical objects and their virtual counterparts, enabling real-time data synchronization, object recognition, and virtual overlays. We designed the system to be flexible and extendable, allowing for future integration of additional objects and curriculum. This research advances the field of engineering education by demonstrating the potential of immersive digital twin environments. The laboratory provides a dynamic learning space where students can experiment, collaborate, and learn without the risks associated with live experimentation. The ability to simulate and manipulate solar installation objects under various conditions has broad implications for workforce development, particularly in renewable energy. The project also highlights the economic feasibility of using XR technologies in educational settings, offering a cost-effective solution for institutions looking to enhance their curriculum. By fostering a deeper understanding of solar energy systems, this work contributes to the broader goal of supporting the global energy transition and preparing the next generation of engineers and technicians.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2025

Myna: Connecting powder bed fusion build data to simulation tools for digital twin applications

Additive manufacturing (AM), as a digital process, can generate a detailed digital thread linking a part’s design and manufacturing to its operational performance. As AM systems advance, an increasing amount of process data is stored in manufacturing databases. In principle, this data can be utilized by simulation-based digital twin approaches, such as real-time process control and asynchronous post-processing guidance. However, few tools currently exist for systematically integrating digital thread data with computational tools. Here, in this study, we propose a software package, called Myna, for connecting data from powder bed fusion processes to simulation tools. The utility of such a platform is demonstrated using build data from the Oak Ridge National Laboratory Manufacturing Demonstration Facility “Peregrine v2023-10” public dataset to automatically configure and run 54 semi-analytical 3DThesis melt pool simulations, 78 numerical Additive FOAM melt pool simulations, and 3 ExaCA microstructure simulations. The simulated, spatially registered microstructures are then compared directly with electron backscatter diffraction characterization of the corresponding as-built part locations. The resulting simulated microstructure showed variation as a function of process parameters, particularly stripe width; however, the experimental data had little variation between the microstructure texture and grain size resulting from different processing conditions. Analysis of the discrepancies suggest that it is possible a two-phase ferritic-austenitic solidification model is needed to accurately predict grain size and texture for certain stainless steel 316L feedstock compositions under powder bed fusion conditions, providing direction for future research. As illustrated here, due to the number and complexity of the simulations involved in AM process-structure–property predictions, automated methods to connect process data and simulations will remain necessary tools for testing hypotheses and implementing digital twin applications.

Knapp, Gerald L. [Oak Ridge National Laboratory (O↗

NASA NTRSDate not supplied

Overview of the National Airspace System (NAS) Digital Twin Simulation Environment

The National Airspace System (NAS) Digital Twin is an environment for building and running diverse, realistic simulations of current or future airspace operations. The environment allows for many different types of simulations including both fast-time and real-time operating modes. Playback of historical or live NAS traffic can be combined with simulated aircraft to create a detailed, live, virtual, and constructive environment. These capabilities go together to create an environment that allows for development of concepts through the entire Technology Readiness Levels scale from initial concept to field evaluations. This extended abstract will discuss details of the software-foundations of the NAS Digital Twin environment. Then, several example simulations and analyses will be presented to illustrate the breadth and power of the tool.

airspace simulation↗

NASA NTRSDate not supplied

Overview of the National Airspace System (NAS) Digital Twin Simulation Environment

airspace simulation, digital twin↗

DOE OSTI2026

Digital Twin Technology for Safety, Security, and Training in Spent Nuclear Fuel Handling

The increasing complexity of spent nuclear fuel handling requires significant resources to ensure safety, security, and personnel training. As nuclear facilities have continued to advance in scale and technology, the integration of digital tools has become indispensable. Among these tools, digital twins, which are virtual models of physical systems, are emerging as invaluable tools for enhancing safety protocols, security measures, and training in the nuclear sector. These models were conceptualized in the Industry 4.0 revolution. Digital twins can process data from physical systems in real time (by using sensors), include multiple code packages to enable simulations of different physics applications, and even implement artificial intelligence or machine learning techniques for advanced data processing. Despite the advantages that digital twins provide, challenges still exist regarding their widespread implementation. For instance, data used by a digital twin must be accurate to ensure that the digital twin is accurately tuned. Furthermore, if insecure digital twins are targeted by hackers, then they can pose serious risks to the security and safety of nuclear facilities.

Digital twins↗

DOE OSTI2025

Twinac: initiation of a community-driven accelerator digital twin framework

We present the initiation of a community-driven framework for the integration of accelerator digital twins into control systems: Twinac. Few facilities have fully integrated accelerator digital twins like at Cornell’s CHESS. Many facilities have active research to employ surrogate models to aid in operational decisions like at Argonne’s ALS, MSU’s FRIB, SLAC’s LCLS-II, and Fermilab’s FAST/IOTA, PIP-II, and main complex. To lower the barrier to entry for all accelerator facilities to build and benefit from a digital twin of their own accelerators, we propose the following software framework. Twinac will provide the capability to compose one’s own digital twin using reusable components engineered at other facilities. With this model in place, Twinac will also support tools for (1) predictive maintenance systems; (2) discovery of correlated but uncontrolled environmental factors, like seasonal temperature variations causing performance changes on power supplies, magnets, etc.; and (3) prototyping and updating sophisticated optimization and controls algorithms. The Twinac framework will enable sharing and simplified deployment of modeled components and control algorithms at all facilities. With an inter-facility team to build and support the Twinac framework, it will be easy to publish and try out the latest advancements at one’s own facility.

Miceli, Tia [Fermilab]↗

DOE OSTI2025

White Paper: Scalable Digital Twin Capabilities for Aging and Surveillance of Engineered Systems

This white paper presents a multi-year initiative to develop practical, secure, and scalable digital twin capabilities for engineered systems in aging and surveillance contexts—an approach pioneered at the National Nuclear Security Administration (NNSA) Lawrence Livermore National Laboratory (LLNL) that maps directly onto the needs and ambitions of the Navy for ship- and fleet-level digital twins. LLNL’s work in building part- and process-level digital twins for advanced manufacturing, with a vision to scale up to entire factory floors and, ultimately, enterprise-wide digital twins, offers an adaptable pathway for the Navy as it seeks to modernize lifecycle management, readiness, and predictive maintenance across ships and fleets. For our application, we integrate physics-based modeling with automated data ingestion, processing, and AI-driven calibration, creating hybrid models that are both interpretable and data responsive. We modernized legacy workflows, established centralized data infrastructure, automated experimental pipelines, and demonstrated end-to-end coupling of accelerated aging data with finite element simulations via optimization and surrogate modeling. The result is a generalizable framework that supports part-level digital twins today and lays the groundwork for future system-level twins suitable for Navy applications.

36 MATERIALS SCIENCE↗

NASA NTRS2022

An Earth System Digital Twin for Flood Prediction and Analysis

An Earth System Digital Twin (ESDT) is a dynamic, interactive, digital replica of the state and temporal evolution of Earth systems. It integrates multiple models along with observation data, and connecting them with analysis, AI, and visualization tools. Together, these enable users to explore the current state of the Earth system, predict future conditions, and run hypothetical scenarios to understand how the system would evolve under various assumptions. The NASA’s Advanced Information Systems Technology (AIST)’s Integrated Digital Earth Analysis System (IDEAS) project is to establish an extensible architectural solution to develop digital twins of our physical environment for Earth Science. IDEAS delivers a formal system architecture with mechanisms for the outputs of one model to feed into others; for driving models with observation data; and for harmonizing observation data and model outputs for analysis. To validate and demonstrate the IDEAS architecture, this project collaborates with the Space Climate Observatory (SCO)’s FloodDAM project and the Centre National d’Etudes Spatiales (CNES) to focus on floods detection, prediction and their impacts.

Kettig, Peter↗

NASA NTRS2024

MBSE (SysML) and Digital Twin Integration to Support Engineering Analysis & Design

Problem Statement: The complexity of Gateway systems and of managing the integrated safety analysis have made traditional methods of engineering analysis and design increasingly challenging. To address these challenges, a prototype that integrate Model-Based Systems Engineering (MBSE) with Digital Twin technology has been developed to demonstrate the utilities and functions. Project Goal: Develop a prototype of a Digital Twin Of Gateway ECLSS IMV system to enhance fault management analysis through collaboration, visualization, and simulation. Overall Project Results / Accomplishments: - Developed extension to streamline the integration of SysML models with the Digital Twin platform - Demonstrated the capability to aggregate any relevant information and provide simulation integration within the DT prototype. - Generated digital twin simulation using SysML Activity Diagrams - Implemented a complex trade study use case based on the integrated SysML-Digital Twin infrastructure

MBSE↗

DOE OSTI2025

Development of a Digital Twin for Hydrogen Dispersion and Safety Assessment in an Electrolyzer Based Hydrogen Production Facility

Digital twin models are virtual representations of physical systems that use real-time data to simulate and optimize performance. This study presents the development and initial implementation of a digital twin (DT) for the electrolyzer-based hydrogen production facility at NREL's Advanced Research on Integrated Energy Systems (ARIES), focused on enhancing safety and optimizing sensor placement through physics-based simulations and metadata integration. The DT incorporates detailed facility-specific information, including component layout, leak locations, and controlled release parameters, to model hydrogen dispersion under varying environmental conditions. Using steady-state computational fluid dynamics (CFD) simulations informed by real meteorological data, such as wind speed, direction, and vertical wind profiles, the DT enables visualization of hydrogen plume behavior and spatial concentration distributions. Comparative analysis between high and low wind speed scenarios illustrates the significant influence of wind dynamics on plume shape and extent, with horizontal momentum dominating dispersion at higher speeds, while buoyancy effects become more prominent under low wind conditions. These simulations generate a rich dataset embedded within the DT, allowing users to assess potential leak outcomes and identify optimal sensor locations based on concentration thresholds. The model supports scenario-based analysis to guide safety strategies and equipment deployment for open-area hydrogen infrastructure. The digital twin thus serves as a dynamic platform for virtual prototyping, providing predictive insight into hydrogen behavior and enhancing risk-informed decision-making. This initial phase establishes a validated foundation for future integration of transient, uncontrolled leak scenarios and real-time sensor feedback, positioning the DT as a critical tool for safety design, operational planning, and adaptive monitoring in hydrogen systems. Overall, the approach demonstrates the value of combining environmental data with digital simulations to inform safer and more efficient deployment of hydrogen technologies.

08 HYDROGEN↗

NASA NTRSDate not supplied

Technology for Earth System Digital Twins

NASA IST Program is now designing and developing Digital Twins of the Earth and/or Earth systems. Earth System Digital Twins (ESDTs) are information systems for understanding, forecasting, and conjecturing the complex interconnections among Earth systems, including anthropomorphic forcings and impacts to humanity. This presentation will address the main technology and architecture challenges that need to be addressed to develop end-to-end ESDTs; along with these challenges, some of the solutions proposed by IST projects will be discussed.

Earth Science Remote Sensing; Information Systems↗

NASA NTRSDate not supplied

Enabling Interoperability in Earth System Digital Twins (ESDT): Integrating Observations, Models, and AI for Actionable Insights Through NASA'S Intelligent Systems Technology Program

NASA’s Intelligent Systems Technology Program (IST) is driving a paradigm shift in Earth science through the development of Earth System Digital Twins (ESDT). These integrated information systems create a dynamic "digital replica" of the Earth by harmonizing continuous, multi-source observations with high-fidelity models and state-of-the-art artificial intelligence (AI) that enable “What now?”, “What next?”, and “What if?” scenario building. These scenarios are reflected in NASA IST’s series of ESDTs, from the Coastal Zone Digital Twin that integrates complex data on the current state of the Chesapeake Bay to the Terrestrial Environmental Rapid-Replication and Assimilation Hydrometeorological (TerraHydro) AI-based ESDT that forecasts water movement across Earth’s surface, to the Agriculture Land Information System (AgLIS) which can be used to assess optimal planting dates and crop yield estimates. By bridging the gap between vast data archives and actionable insights, these projects enable a system-of-systems approach to understanding complex, interacting Earth processes. This poster will highlight recent innovations and future directions from NASA’s ESDT initiatives: Continuous Data Assimilation & Multi-Source Fusion. A core requirement of the ESDT work is the transition from static models to dynamic "living" replicas. This involves creating frameworks for the continual assimilation of near-real-time data from uncoordinated, heterogeneous sources, including satellite observations and airborne assets, and ground-based Internet of Things (IoT) sensors. These systems link design, operational status, and environmental data, ensuring the digital twin accurately reflects the current state of the physical Earth system. High-Fidelity Hybrid Modeling & Computational Acceleration to enable interactive "what-if" explorations, programs are moving beyond traditional, slow physical solvers by developing fast surrogate machine learning models and Deep Generative Models (DGMs). These hybrid approaches use neural networks to emulate complex physics, such as cloud feedback or ocean dynamics, at a fraction of the original computing cost, often leveraging advanced hardware like Graphics Processing Units (GPUs) to achieve the necessary scale. Federated Ecosystems & Interoperable Frameworks rather than building isolated tools, NASA IST is moving toward federated ESDTs and reusable analytic collaborative frameworks. This theme focuses on interoperability standards and common ontologies that allow specialized digital twins to interact and share data. This system-of-systems architecture supports multi-discipline investigations, such as analyzing how upstream watershed changes impact downstream urban flooding or how wildfire emissions affect regional air quality. By leveraging these advancements, ESDTs empower researchers and decision-makers to conduct real-time analysis and run complex hypothetical scenarios, ultimately improving our understanding of Earth’s evolving systems and informing critical real-world applications.

Earth System↗

DOE OSTI2025

Multi-agent AI collaboration for digital twin development and assessment

Developing a digital twin (DT) model involves different steps that encompass formulating requirements, model development, implementation, and assessment with respect to real applications. Human expertise is required to coordinate and implement different steps in the DT development and assessment process. However, certain parts of this process can be automated using artificial intelligence (AI) agents for efficient workflow development. In this work, we test and analyze a multiagent AI collaboration with humans in the loop to automate different elements of the DT development and assessment process. To implement the workflow for multiagent AI DT development and assessment, we use Autogen, a multiagent framework developed by Microsoft. Autogen offers a modular and flexible framework for configuring and designing task-specific multiagent workflows. In this framework, large language models (LLMs) form the core intelligence of the AI agents where the quality and performance of the automated element is governed by the inherent capabilities and knowledge base of the LLM. We use retrieval augmented generation to supplement the LLM with relevant domain-specific information for DT requirement formulation. We illustrate this multiagent workflow using a case study on a thermal energy storage system, focusing on how AI agents can collaborate with humans to expedite and optimize different elements of DT development and assessment process.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2026

Development of a Digital Twin for Hydrogen Dispersion and Safety Assessment in an Electrolyzer-Based Hydrogen Production Facility: Preprint

Digital twin models are virtual representations of physical systems that use real-time data to simulate and optimize performance. This study presents the development and initial implementation of a digital twin (DT) for the electrolyzer-based hydrogen production facility at the National Renewable Energy Laboratory (NREL)'s Advanced Research on Integrated Energy Systems (ARIES), focused on enhancing safety and optimizing sensor placement through physics-based simulations and metadata integration. The DT incorporates detailed facility-specific information, including component layout, leak locations, and controlled release parameters, to model hydrogen dispersion under varying environmental conditions. Using steady-state computational fluid dynamics (CFD) simulations informed by real meteorological data, such as wind speed, direction, and vertical wind profiles, the DT enables visualization of hydrogen plume behavior and spatial concentration distributions. Comparative analysis between high and low wind speed scenarios illustrates the significant influence of wind dynamics on plume shape and extent, with horizontal momentum dominating dispersion at higher speeds, while buoyancy effects become more prominent under low wind conditions. These simulations generate a rich dataset embedded within the DT, allowing users to assess potential leak outcomes and identify optimal sensor locations based on concentration thresholds. The model supports scenario-based analysis to guide safety strategies and equipment deployment for open-area hydrogen infrastructure. The digital twin thus serves as a dynamic platform for virtual prototyping, providing predictive insight into hydrogen behavior and enhancing risk-informed decision-making. This initial phase establishes a validated foundation for future integration of transient, uncontrolled leak scenarios and real-time sensor feedback, positioning the DT as a critical tool for safety design, operational planning, and adaptive monitoring in hydrogen systems. Overall, the approach demonstrates the value of combining environmental data with digital simulations to inform safer and more efficient deployment of hydrogen technologies.

08 HYDROGEN↗