Implementation and Manufacturing of DT Sensor Ecosystem for Real-Time Monitoring of Virtual 3D Printers

A full-featured digital representation of all the characteristics of a physical system or object is known as a Digital Twin (DT) and smart manufacturing is made possible in large part by our relationship to the environment. A DT system is simulated in real time and with high accuracy. While, maintaining constant synchronization provides a comprehensive system with physical system management. The use of a DT for a 3D printer is covered in this article which presents the 3D printer’s settings and relevant warnings in real time and uses a lightweight Augmented Reality (AR) model to let users control the basic printer functions that encourage communication between two parties. The tri-model simulates actual physical behavior while operating simultaneously and digital model features. To verify the architecture and method that have been proposed, further investigation is done using a case study of a DT facility using open-source 3D printing. Additionally, future research and conclusions are highlighted to offer illuminating information finally to the two industries and the academic world. We have an economical DT ecosystem, robust and reproducible, thereby allowing the addition of DT capabilities to legacy equipment; creating analytics using historical data that have been collected. © 2023, The Author(s), under exclusive licence to Springer Nature Singapore Pte Ltd.