Adaptive digital twins for predictive decision-making: Online Bayesian learning of transition dynamics

Here, we explore the problem of error propagation mitigation in modular digital twins as a sequential decision process. Building on a companion study that used a Hidden Markov Model (HMM) to infer latent error regimes from surrogate-physics residuals, we develop a Markov Decision Process (MDP) in which the inferred regimes serve as states, corrective interventions serve as actions, and a scalar reward that takes into consideration the cost-benefit tradeoff between system fidelity and maintenance expense. The baseline transition matrix is extracted from the HMM-learned parameters. We then extend the formulation to a Partially Observable MDP (POMDP) that accounts for the imperfect nature of regime classification by maintaining a belief distribution updated via Bayesian filtering, with the HMM confusion matrix serving as the observation model. Both formulations are solved via dynamic programming and validated through Gillespie stochastic simulation. We then benchmark two model-free reinforcement learning algorithms, Q-learning and REINFORCE, to assess whether effective policies can be learned without explicit model knowledge. A systematic comparison of different intervention policies demonstrates that the MDP policy achieves the highest cumulative reward and fraction of time in nominal operation, while the POMDP recovers approximately 95% of MDP performance under realistic observation noise. Sensitivity analyses across observation quality, repair probability, and discount factor confirm the robustness of these conclusions, and the major gaps in the policy hierarchy are statistically significant at $p < 0.001$. The gap between MDP and POMDP performance quantifies the value of information providing a principled criterion for investing in improved classification accuracy.

Digital Twins rely on surrogate models to mirror physical systems in real time, yet these models can degrade as operating conditions evolve, a phenomenon known as concept drift. Maintaining surrogate fidelity under drift, particularly when models must also capture aleatoric uncertainty, remains an open challenge. Existing adaptive frameworks lack principled mechanisms for detecting when updates are needed, for efficiently adapting models from limited streaming data, and for certifying that updates genuinely improve predictive performance. Here we present an adaptive Digital Twin framework that integrates a Fisher score--based multivariate drift detector, Low-Rank Adaptation (LoRA) for parameter-efficient continual learning, and a Mann--Whitney $U$ test for online statistical validation. The framework monitors surrogate-model confidence via Fisher score vectors, triggers targeted fine-tuning of fewer than 1% of model parameters upon drift detection, and statistically certifies predictive improvement before deploying the updated surrogate. Applied to a stochastic linear system and a directed energy deposition additive manufacturing process as case studies, the framework successfully detects distributional shifts with short delays and restores both predictive accuracy and uncertainty quantification under abrupt and incremental drift. These results establish a statistically rigorous and computationally tractable pathway for sustaining the trustworthiness of neural-network--based Digital Twins throughout their operational life cycle.

A digital twin (DT) is a virtual model of a real-world system that can assist decision-making by simulating scenarios induced by different policies. However, typical machine learning-based DTs do not optimise for this use case. We prove that, when model capacity is limited, training DTs to minimise one-step transition errors can produce suboptimal models for ranking sets of policies according to a reward function. We further show that this holds empirically, even with expressive model classes. To address this, we introduce $\text{DT}^2$, a decision-targeted DT training paradigm. Firstly, $\text{DT}^2$ uses fitted Q-evaluation to estimate values of candidate policies from offline data. A DT is then trained to generate rollouts that preserve pairwise policy rankings derived from these proxy ground-truth values with an architecture-agnostic loss function. We empirically demonstrate the efficacy of our method across a range of settings and architectures. $\text{DT}^2$ consistently improves policy ranking and reduces decision regret during policy selection relative to conventional DT training, both for policies used during training and for unseen policies, while maintaining a good level of raw simulation fidelity.