A Continual Validation, Updating, and Decision-Making Framework for Self-Adaptive Digital Twins via Robust Model Predictive Control: A Case Study in Additive Manufacturing
Authors: Yi-Ping Chen, Ying-Kuan Tsai, Vispi Karkaria, Seul Lee, Daniel Apley, Wei Chen
Organizations: Department of Mechanical Engineering, Northwestern University · Department of Industrial Engineering and Management Science, Northwestern University
Abstract
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.
This work shows how adaptivity can enhance value realization of digital twins in civil engineering. We focus on adapting the state transition models within digital twins represented through probabilistic graphical models. The bi-directional interaction between the physical and virtual domains is modeled using dynamic Bayesian networks. By treating state transition probabilities as random variables endowed with conjugate priors, we enable hierarchical online learning of transition dynamics from a state to another through effortless Bayesian updates. We provide the mathematical framework to account for a larger class of distributions with respect to the current literature on digital twins. To compute dynamic policies with precision updates we solve parametric Markov decision processes through reinforcement learning. The proposed adaptive digital twin framework enjoys enhanced personalization, increased robustness, and improved cost-effectiveness. We assess our approach on a case study involving structural health monitoring and maintenance planning of a railway bridge.
Digital twins of natural systems must remain aligned with physical systems that evolve over time, are only partially observed, and are typically modeled by mechanistic simulators whose parameters cannot be measured directly. In such settings, model adaptation is naturally posed as a simulation-based inference problem. However, sparse and indirect observations often fail to identify a unique and optimal calibration, leaving several simulator parameterizations compatible with the available evidence. This article presents a GFlowNet-based approach to model adaptation for digital twins of natural systems. We formulate adaptation as a generative modeling problem over complete simulator configurations, so that plausible parameterizations can be sampled with probability proportional to a reward derived from agreement between simulated and observed behavior. Using a controlled environment agriculture case study based on a mechanistic tomato model, we show that the learned policy recovers dominant regions of the adaptation landscape, retrieves strong calibration hypotheses, and preserves multiple plausible configurations under uncertainty.
Real-time supervisory control of thermal energy distribution systems requires digital twins that are accurate, interpretable, and uncertainty-aware, yet remain data and computationally efficient. High-fidelity simulations alone are costly, while purely data-driven surrogates often lack robustness. To address these challenges, this work proposes an active learning (AL) framework that couples system-level Modelica simulations with four simpler physics-informed and data-driven surrogate modeling approaches: deterministic Sparse Identification of Nonlinear Dynamics with Control (SINDyC), its probabilistic multivariate-Gaussian extension (MvG-SINDyC), feedforward neural network (FNN), and gated recurrent unit (GRU) network. Tailored to each surrogate, model-specific AL query strategies are employed, including Mahalanobis-distance sampling in coefficient space for MvG-SINDyC and error-based sampling in prediction space for SINDyC, FNN, and GRU, allowing the learning process to prioritize dynamically informative trajectories. The proposed approach is demonstrated on the glycol heat exchanger (GHX) subsystem of the Thermal Energy Distribution System (TEDS) at Idaho National Laboratory. Across key GHX outputs--the bypass mass flow rate m˙GHX and heat transfer rate QGHX-the AL framework achieves comparable predictive accuracy using as few as one-fifth of the simulation trajectories required by random sampling. Among the evaluated surrogates, the GRU achieves the highest predictive fidelity, while SINDyC remains the most computationally efficient and interpretable. The probabilistic MvG-SINDyC surrogate further enables uncertainty quantification and exhibits the largest computational gains under AL.