An analysis of the technical challenges to produce a Digital Twin of FDM parts

Abstract

A Digital Twin (DT) is a digital representation containing all relevant information of a physical entity with synchronization between the entity and its virtual representation. The Digital Twin is mainly used to monitor, control and predict a part or process. Many challenges exist in implementing Digital Twins in the Additive Manufacturing (AM) fabrication process. However, recent advancements in sensorization and simulation make DT more useful for AM processes and ease its adoption. While FDM parts are commonly used in non-load bearing functions, with the aid of DT, it is possible to improve the mechanical properties and geometrical accuracy of the parts, which can help expand their use in engineering applications. This work evaluates the challenges and benefits of creating a Digital Twin for FDM products and proposes a methodology for gathering the relevant information.