Advancing Aerospace Manufacturing with Digital Twins Digital Twin Consortium at the 8th IEEE International Conference on Space Mission Challenges for Information Technology
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Regional surrogates for predictive control of digital twins
Digital twins of complex systems must involve a model that is fast, generalizable, and usable for real-time control. For example, high-fidelity nonlinear multiphysics simulations can capture laser-material interactions, but are too slow for optimization or model predictive control (MPC). Reduced-order models, used to accelerate such computation, frequently fail to generalize to unseen inputs or control states. We show theoretically that this failure is intrinsic, i.e., that a learned model is non-unique outside the sampled subspace when its low-rank structure arises from limited excitation and clustered eigenvalues, rather than from a user-imposed truncation alone. Motivated by this result, we propose a control-ready regional surrogate-construction framework for both autonomous and nonautonomous dynamics; it employs Koopman lifting to represent nonlinearities, while preserving spatial locality. We illustrate our approach by constructing a control-ready surrogate for the digital twin of a thermal component of additive-manufacturing process. Our surrogate, localized in space through a von Neumann stencil, is learned from noisy high-fidelity simulations that emulate thermal-camera images collected during the manufacturing. It is linear in thermo-physically augmented states so that MPC reduces to a convex quadratic program. The surrogate requires no online correction, generalizes to unseen scan paths and power profiles of the laser, and is more than three orders of magnitude faster than a finite-difference solver. Furthermore, when the MPC sequence computed on the digital twin is applied to this solver, closed-loop temperature regulation is recovered, showing that the surrogate preserves control-relevant input-output behavior.
Data-driven model↗
NASA Earth Science Technology Office (ESTO) Advanced Information Systems Technology (AIST) Program: Earth Systems Digital Twins (ESDT) Standards for Interoperable Digital Twins Workshop Presentations
On September 18, 2023, NASA Earth Science Technology Office (ESTO) Advanced Information Systems Technology (AIST) Program conducted a mini-workshop that brought together seven experts to survey and discuss "Standards for Interoperable Digital Twins". Since three years, the AIST Program has been developing technologies and prototypes for Earth System Digital Twins (ESDT). During those developments and after the ESDT Workshop held in October 2022, it became clear that standard for ESDT interoperability were needed and should be defined as soon as possible. To address this challenge, the AIST program will survey ongoing development for Digital Twins standards in various domains and the September 18, 2023 Workshop represented the first step towards this understanding. Speakers during this event included: Michael Grieves (Digital Twin Institute), Siri Jodha Singh Khalsa (IEEE GRSS Standards), Trent Tinker (OGC), Ryan Berkheimer (NOAA), John Stone (NVIDIA), Thomas Geenen (ECMWF-DestinE) and Arne Berre (SINTEF-Iliad DTO and EDITO). This presentation regroups all the speakers' presentations.
Earth Science Remote Sensing; Information Systems↗
Automated Signal Timing Plan Reconstruction Using High-Resolution Event-Based Controller Data for Digital Twins
Transportation digital twins are essential tools for evaluating emerging technologies such as connected and automated vehicles, adaptive traffic signal control, and mobility optimization strategies. Realistic digital twins require accurate emulation of real-world signal controllers and detailed signal timing plans. However, signal timing plans are often unavailable or difficult to access, forcing researchers and modelers to rely on assumed fixed timings or halt their analysis. To overcome this challenge, we present a method that directly estimates signal timing plan parameters using high-resolution, event-based data from traffic signal controllers. The proposed method extracts key parameters, including cycle length, offset, phase sequence, coordinated phases, phase-specific minimum and maximum green durations, vehicle extensions, and splits under coordination. A rule-based deterministic signal timing reconstruction algorithm based on traffic signal operation rules, such as those outlined in the Signal Timing Manual, is developed and validated. We evaluate this method, which uses high-resolution controller event logs and verified signal timing plans, on 94 signalized intersections in Nashville, Tennessee, demonstrating their ability to generate accurate, simulation-ready signal timing plans for tools such as SUMO and Vissim.
Saroj, Abhilasha [ORNL] (ORCID:0000000191178063)↗
Digital twin framework for PIP-II linac: AI-driven multi-scale modeling from ion source to 800 MeV
The PIP-II superconducting linac at Fermilab is designed to deliver multi-megawatt proton beams for neutrino physics and other high-intensity applications. To expedite commissioning and enhance operational reliability, we have developed an EPICS-based data flow framework that seamlessly integrates digital twins (DT) with physical twins (PT). These digital twins comprise high-fidelity beam dynamics models or data-driven surrogate models connected to their physical counterparts through real-time diagnostics and advanced machine-learning algorithms.Central to this framework is Linac_Gen, an accelerated simulation tool that incorporates convolutional neural networks, random forests, and genetic algorithms to provide up to a tenfold speedup in optimizing the accelerator geometry model. An EPICS translator layer ensures interoperability by efficiently mapping lattice parameters across diverse simulation platforms.Our EPICS-based framework supports multiple operational modes—monitoring, passive learning, closed-loop control, and online learning—covering the entire machine lifecycle. By leveraging HPC resources and multi-objective optimization techniques, the digital twin enables adaptive trajectory correction, real-time fault detection, and predictive modeling of beam stability. This comprehensive approach paves the way for robust, high-intensity operation and data-driven accelerator R&D at Fermilab.
Pathak, Abhishek [Fermilab]↗
Throughput Estimation of Data Transport Networks From Digital Twin Measurements
Digital twins of networked infrastructures, known as Virtual Infrastructure Twins (VITs), are increasingly used for software development, pre-deployment testing, and design space exploration. While VITs avoid the costs and potential disruptions associated with experiments on operational networks, their throughput measurements are typically not sufficiently accurate for performance profiling of wide-area networks that they emulate. Here, machine learning (ML) methods are developed to transform these inaccurate VIT network throughput measurements to closely match in peak and overall profile of those from a physical testbed or production network. First, a micro kernel network reflecting a physical network is utilized to collect one-time measurements on a host to support this ML transformation. Then, a generic multi-modal ML method is developed to learn a map that transforms measurements from subsequent VITs on the same host to match past, current and follow-on testbed and cloud networks. ML generalization equations are derived to establish its correctness and probabilistically guarantee its generalization accuracy. Experimental results are presented for a variety of VIT hosts with target testbed and cloud networks; they include a case study of a four-site science ecosystem wherein inaccurate convex VIT measurement profiles are transformed into accurate concave profiles of target networks.
97 MATHEMATICS AND COMPUTING↗
Information Systems Technology for NASA Earth Systems Digital Twins (ESDT)
The term “Digital Twin” was first used in 2002 for product lifecycle management. Since then, Digital Twin concepts have been proposed in various domains until very recently for Earth Science. For NASA’s Advanced Information Systems Technology (AIST) Program, an Earth System Digital Twin (ESDT) is defined as composed of three components: 1. A Digital Replica, i.e., an integrated picture of the past and current states of Earth systems 2. Forecasting capabilities, providing an integrated picture of how Earth systems will evolve in the future from the current state 3. Impact Assessment capabilities, providing an integrated picture of how Earth systems could evolve under different hypothetical what-if scenarios. Developing such a vision will require technologies related to: integrating continuous observations from various disparate sources; developing frameworks that builds on inter-connected models; improving the speed and accuracy of integrated prediction, analysis and visualization capabilities (e.g., by using machine learning); and utilizing causality and uncertainty quantification to improve our understanding of the evolution of Earth Science systems as a function of their interactions with other Earth and human systems. In addition, AIST is also investigating interoperability standards to federate multiple Digital Twins, as well as computational resources required by those systems.
Earth Science Remote Sensing; Information Systems↗
Earth System Digital Twins (ESDT)
"First Webinar for a digital twin webinar series titled ""Digital Twin Webinar Series 1: Concept, Practices, and Vision"". This kick-off webinar will focus on concepts, architecture and high level discussion on digital twins for Earth science and other domain sciences. The agenda will be the following: - Dr. Jacqueline Le Moigne is NASA AIST program manager, and the first federal program manager to programmatically fund 14 digital twin research projects. - Mr. Stan Posey is the HPC Program Manager, ESM and CFD Domains at NVIDIA. - Dr. Goodchild is a emeritus professor at UCSB, member of the national academy, and a founder of digital earth international society."
Information Systems↗
Beartooth - Digital Twin Framework Enabling AI
Digital twin was designed as a core part of this testbed. This presentation will discuss the digital twin framework that will enable AI for nuclear aqueous seperations.
11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
Latency Analysis of the Nexus Digital Twin Framework
Real-time digital catalogs are increasingly relied upon to track metadata and connect disparate data sources for cloud-based data integration efforts. One such tool, Deeplynx Nexus is supporting real-time digital twin efforts through event-driven data integration and time-series queries. Nexus’s usefulness for these applications depends critically on how quickly individual records can be uploaded and downloaded, since delays directly affect the responsiveness of any system built on top of it. However, the actual latency a user should expect from Nexus has not been systematically measured before, particularly for the small, frequent transactions typical of live sensor feeds. Here we show that single-record round-trip latency is 61.1 ms on a local Nexus instance and 391.7 ms on the hosted production infrastructure, a roughly 6.4x difference driven primarily by fixed per-request overhead rather than data volume. This overhead dominates at small scale: comparing single-record and ten-record trials suggests approximately 56 ms of each single-record request is fixed connection and authentication cost rather than data-transfer time, meaning batching even a handful of records is substantially more efficient than transmitting them individually. At large batch sizes, this pattern reverses for uploads, which converge to near parity between local and hosted environments by 25,000-50,000 records, while download latency remains persistently 5.7-6.4x slower on hosted infrastructure even at scale. These results suggest that Nexus deployments intended for real-time digital twin applications should prioritize record batching over single-record transactions, and that download-path optimization on hosted infrastructure offers the largest remaining opportunity to reduce latency at scale. We anticipate these baseline measurements will serve as a reference point for future digital twin projects evaluating whether Nexus’s latency profile meets their real-time requirements, and as a benchmark for tracking the effect of future infrastructure or API changes.
99 - GENERAL AND MISCELLANEOUS↗
ECLSS Four-Bed CO2 Scrubber Digital Twin
The ECLSS Digital Twin is a cloud-based simulation of the Four-Bed CO2 Scrubber, currently one of the primary means of removing carbon dioxide onboard the International Space Station, that operationalizes SME-developed multi-physics models and replicates conditions of the actual hardware in near real-time. In addition to providing insight into the system’s performance, it will enable prognostics, diagnostics, predictive maintenance, and simulated off-nominal scenarios. By leveraging digital representations, projects can save resources and gain a better understanding of their physical systems with the goal of building robust and reliable hardware for future deep space exploration. The use of data infrastructure in the cloud allows for streamlined analysis and visualization on a much larger scale than is possible with current tools.
Jared Wilson↗
Advanced Information Systems Technology for NASA Earth System Digital Twins (ESDT)
ESA and NASA have both started programs to design and develop Digital Twins of the Earth and/or Earth systems. Organized around interconnected, multi-domain, high-scale modeling capabilities, the three major components of an Earth System Digital Twin are a continuously updated Digital Replica of the Earth System of interest, dynamic Forecasting models, and Impact Assessment capabilities. Earth System Digital Twins integrate diverse Earth and human activity models, continuous observations, and information system capabilities to provide unified, comprehensive representations and predictions that can be utilized for monitoring the health of the Planet, as well as for developing actionable information to support decision making. More generally, Digital Twins will help researchers better understand the fundamental Earth systems that impact everything from wildfires to climate change. This Townhall will first provide a short description of ESA’s, NASA’s and CNES’s current efforts in Digital Twins: • Destination Earth (DestinE) is the first initiative of the European Union to create a Digital Twin of the Earth, particularly focused on weather and climate, and as a coordinated effort between the European Centre for Medium-Range Weather Forecasts (ECMWF), ESA and the European Organization for the Exploitation of Meteorological Satellites (EUMETSAT). • Additionally, ESA is developing several Digital Twin Earth Precursor Activities to study some of the key scientific and technical challenges associated with building a “Digital Twin Earth”. These include forests, hydrology, Antarctica, food systems, oceans, and climate hot spots Digital Twin prototypes. • NASA Earth Science Technology Office (ESTO)’s Advanced Information Systems Technology (AIST) Program has started an initiative in Earth System Digital Twins (ESDT), with 14 current projects in this area, developing various information systems technologies and prototypes that will help prepare the development of future NASA Digital Twins. • CNES is currently developing the concept of a Digital Twin Factory (DTF), which relies on a data lake, a high computing capability using clouds and/or HPC and has thematic algorithms and methodologies able to generate registered and coherent layers of information in order to enrich a datacube from which physical indicators can be computed spatially. NASA, ESA and CNES are also currently defining science use cases that will be presented during the townhall; those and a few short discussions of current projects will serve as a starting point to engage a dialogue about Digital Twins of the Earth with the IGARSS community.
earth science remote sensing; Information systems↗
Developing a digital twin framework for remotely monitoring nuclear reactor facilities
A digital twin must seek to represent all applicable functional components of the system of interest. Different expertise is required for understanding the physical system being modeled than the skills needed for transforming those models into a functional digital twin through physics modeling, machine learning analysis, and visualization. The diversity of knowledge requires a multi-disciplinary team to ensure all system details are captured. Team members also need a method to verify that the data they generate within their domain can be effectively communicated to professionals in other fields. To address this challenge, this work provides an approach for developing a digital twin framework to remotely monitoring nuclear facilities. Through this, general knowledge of the framework is presented along with two examples to solidify the process. The AGN-201 digital twin and microreactor digital twins provide varying levels of complexity in a potential nuclear facility, where common threads are identified and lessons learned are provided. The goal of this research is to aid future researchers by providing a formula for a successful digital twin and in turn reducing the development time of nuclear system digital twins, specifically for remote monitoring.
22 - GENERAL STUDIES OF NUCLEAR REACTORS↗
Operational resilience of additively manufactured parts to stealthy cyberphysical attacks using geometric and process digital twins
Cyberphysical attacks on the digital backbone of Additive Manufacturing (AM) can compromise the printed part’s functionality. They can alter features in the digital geometry to introduce geometric defects (e.g., missing fillets) or alter process parameters to create local defects (e.g., voids). Addressing the downtime, waste, and quality deterioration associated with existing solutions requires operational resilience, i.e., rapid elimination or disruption of defect formation (to retain part function) without production stoppage or part disposal (to retain yield). This need is unmet due to the inherently unpredictable nature of attack-induced alterations, lack of access to the original geometric model for identification of altered geometric features, and in-process imposition of unknown process dynamics via attack-driven alteration of real-time-uncontrolled (or exogenous) parameters. This work establishes the above-mentioned operational resilience for the first time by creating two Digital Twins (DT). The Geometric DT (Geo-DT) is based on a unique physical-field-driven soft sensor and topology optimization method. The Process Digital Twin (Pro-DT) combines local defect quantification with a novel Reinforcement Learning formulation and training method. The importance of these methodological advances and the scalability of our approach are examined on a real AM testbed. It is shown that Geo-DT can correct geometric defects without access to the original digital geometry or explicit knowledge of attack-altered geometric features. Further, Pro-DT can accelerate real-time disruption of local defects despite attack-driven imposition of unknown process dynamics. We discuss how our framework goes beyond the contemporary focus on pre-attack security and in-attack detection towards resilience for AM and beyond.
Additive Manufacturing↗
NASA Earth Systems Digital Twins (ESDT)
"Similarly to artificial intelligence, which is now revolutionizing many aspects of our daily lives, Earth system digital twin technologies have the potential to revolutionize the way Earth Science research will be conducted in the future, and how results and knowledge from this research will provide information to support decision making and yield impactful societal benefits. An Earth System Digital Twin or ESDT is a dynamic and interactive information system that first provides a digital replica of the past and current states of the Earth or Earth system as accurately and timely as possible; second, allows for computing forecasts of future states under nominal assumptions and based on the current replica; and third, offers the capability to investigate many hypothetical scenarios under varying impact assumptions. In other words, an ESDT provides the integrated What-Now, What-Next, and What-If pictures of the Earth or Earth system, by continuously ingesting newly observed data and by leveraging multiple interconnected models, machine learning as well advanced computing and visualization capabilities. Digital twins have been developed in engineering since 2002, but the interest in digital twins for the Earth domain is more recent and stems from the convergence of several developments: - The huge amount of diverse data that has now been collected continuously for more than 50 years, and that is becoming more and more difficult to access, understand, and utilize. - At the same time, because of climate change and its impacts the information produced by all of this data is becoming of interest to many new non-traditional users for analyzing and predicting various phenomena. - Because of advances in computational and visualization capabilities and the parallel unprecedented development of machine learning (ML), extracting relevant information from these large amounts of data and running complex models faster has become possible. As a result, it is becoming necessary and possible to build intuitive and interactive frameworks that will enable users with various skill levels and/or organizational hierarchy levels to easily access large amounts of targeted information along with the relevant tools and models (Earth system and human activity models), to support them in analyzing and visualizing this information, to help them understand interactions among models, to visualize the potential outcomes of various impacts, and to support decision or policy making. The full power of digital twins is that, through an integrated representation and standardized tools and software technologies, the same digital replica can address the needs of multiple users at various resolutions (spatial and temporal) and for various applications (science, economic, policy, etc.) – “from farmer to scientist”. With all these interests at stake, the challenges of building optimal digital twins are many and complex. The first challenge is to determine if a Digital Twin should be global or local, and multi-domain or thematic. For example, some domains such as Climate or Weather will require a global Digital Twin or Digital Twin capabilities while science areas such as Biodiversity might be more local. We can also envision that multiple thematic ESDTs, e.g., Air Quality, Wildfires, Hydrology could be federated or provide input to other ESDTs, either on a regional level or to a more global ESDT. Overall, we can imagine a future “web” of Digital Twins co-existing in a hierarchy or in a network, and capable of being connected or federated depending on the needs. This last point brings up the very important challenge of interoperability, including standards and protocols that will need to be built into these systems from the beginning. Each individual digital twin would have full flexibility in internal construction but would need standards-based interfaces (input and output) or hooks to make it compatible with others. Another challenge when building digital twins will be to decide how to organize each digital replica. Based on the applications targeted by the DT under implementation, various amounts and types of raw data, Analysis Ready Data (ARD) and information will need to be incorporated. Depending on the required latencies and needs of the users, various solutions can be considered, including Data Cubes, Data Lakes, pointers, or computing information on demand. We envision that each ESDT will choose a solution adapted to its specific objectives. Another important challenge is the type(s) of visualization that will be used, as well as the level of interactivity and refresh rate that will be required. Again, this will depend on the objectives of the ESDT, but also on the various users’ needs. In most cases, several types of visualizations and human interfaces will need to be offered depending on the projected users of that system. In parallel to the challenges highlighted above, there are also many tools and technologies that will need to be developed or improved for all types of digital twins. Among those are improved machine learning technologies, for example providing explainability, but also ML techniques for causality and providing a better integration of physics models. Additionally, reliable uncertainty quantification methods will be needed for all ESDT components, from validating data fusion and assimilation to assessing the accuracy of ML models and weighing the values of decisions supported by those systems. This presentation introduces the ESDT concept, presents several ESDT use cases, and a proposed ESDT architecture framework, as well as various technologies being developed by the Advanced Information Systems Technology (AIST) Program."
Earth Science Remote Sensing; Information Systems↗
Towards a Robust Adaptive Digital Twin for Fusion Applications
The development of a digital twin system for fusion applications is essential for enhancing the prediction, analysis, and optimization of complex plasma processes. Machine learning (ML), particularly deep learning has demonstrated strong capabilities in modeling such highly nonlinear and intricate systems. However, two critical challenges limit the deployment of deep learning-based digital twins: Uncertainty Quantification (UQ) and data drift. UQ is vital for ensuring trustworthy predictions, especially in decision-support scenarios. Additionally, data-driven models are often sensitive to changes in the underlying data distribution, such as shot-to-shot variations in fusion experiments, which can lead to performance degradation over time. To address these challenges, we are developing an uncertainty-aware, adaptive digital twin framework. Our approach incorporates deep learning models enhanced with Gaussian Process approximations for predictive uncertainty estimation, coupled with an online learning mechanism that enables continuous model adaptation to new experimental data. This adaptive capability allows the data driven models to respond effectively to evolving plasma behaviors and equipment conditions. Specifically, to mitigate the effects of shot-to-shot drift, our system updates itself incrementally as new data becomes available, improving both robustness and fidelity. Our vision is to evolve this data driven model into a self-sustaining digital twin system that leverages UQ based feedback to continuously refine itself and potentially support real-time decision making. This presentation will cover a brief background on uncertainty quantification for ML, our ongoing effort on development of UQ capabilities for ML, our data science pipeline from data collection to model development and analysis and online learning framework for modeling coil deflection at DIII-D. I will also briefly touch upon opportunities and challenges in development of digital twin framework.
Sammuli, Brian [General Atomics]↗
NASA Earth System Digital Twins (ESDT) For a Sustainable Future
An Earth System Digital Twin (or ESDT) is an Information System for Understanding, Forecasting, and Conjecturing the complex interconnections among Earth systems, including anthropomorphic forcings and impacts to humanity. More specifically, an Earth System Digital Twin is a dynamic and interactive information system that first provides a digital replica of the past and current states of the Earth or Earth system, as accurately and timely as possible (i.e., the “What Now”); second allows for computing forecasts of future states under nominal assumptions and based on the current replica (i.e., the “What Next”); and third offers the capability to investigate many hypothetical scenarios under varying impact assumptions (i.e., the “What If”). The full power of digital twins is that, through an integrated representation and standardized tools and software technologies, the same digital replica can address the needs of multiple users at various resolutions (spatial and temporal) and for various applications (science, economic, policy, etc.) – “from farmer to scientist”. Since 2020, NASA’s Earth Science Technology’s Intelligent Systems Programs have started defining and investigating ESDTs. After several workshops, more than 15 projects have been funded to develop technologies and components as well as a few prototype ESDT systems. An ESDT architecture framework has been defined, and it is now being used to develop a Coastal Zone Digital Twin (CZ-DT), in coordination with NOAA and CNES. Additional projects have also just been selected to build additional ESDT technologies and prototypes. The details of these Programs will be detailed at the conference.
Earth Science Remote Sensing; Information Systems↗
TIE02. IGARSS’2024 Townhall on “Digital Twins for Earth Science
NASA, ESA, NOAA, CNES and several other international organizations have started programs to design and develop Digital Twins of the Earth and/or Earth systems. Earth Systems Digital Twins (ESDTs) are dynamic and interactive information systems for understanding, forecasting, and conjecturing the complex interconnections among Earth systems, including anthropomorphic forcings and impacts to humanity. Organized around interconnected, multi-domain, high-scale modeling capabilities, the three major components of an Earth System Digital Twin are a continuously updated Digital Replica of the Earth System of interest (or “What Now”), dynamic Forecasting models (or “What Next”), and Impact Assessment capabilities (or “What If”). ESDTs provide unified, comprehensive representations and predictions that can be utilized for monitoring the health of the Planet, as well as for developing actionable information to support decision making. More generally, Digital Twins will help researchers better understand the fundamental Earth systems that impact everything from wildfires to climate change. This Townhall will provide a status of Destination Earth as well as ESA’s, NASA’s, CNES’s and NOAA’s current independent and common efforts in Digital Twins; then the four organizations will provide information about community building before engaging a dialogue about Digital Twins of the Earth with the IGARSS community.
Earth Science Remote Sensing; Information Systems;↗