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Digital twin (DT) is an emerging technology that enables sophisticated interaction between physical objects and their virtual replicas. Although DT has recently gained significant attraction in both industry and academia, there is no systematic understanding of DT from its development history to its different concepts and applications in disparate disciplines. The majority of DT literature focuses on the conceptual development of DT frameworks for a specific implementation area. Hence, this paper provides a state-of-the-art review of DT history, different definitions and models, and six types of key enabling technologies. The review also provides a comprehensive survey of DT applications from two perspectives: (1) applications in four product-lifecycle phases, i.e. product design, manufacturing, operation and maintenance, and recycling and (2) applications in four categorized engineering fields, including aerospace engineering, tunneling and underground engineering, wind engineering and Internet of things (IoT) applications. DT frameworks, characteristic components, key technologies and specific applications are extracted for each DT category in this paper. A comprehensive survey of the DT references reveals the following findings: (1) The majority of existing DT models only involve one-way data transfer from physical entities to virtual models and (2) There is a lack of consideration of the environmental coupling, which results in the inaccurate representation of the virtual components in existing DT models. Thus, this paper highlights the role of environmental factor in DT enabling technologies and in categorized engineering applications. In addition, the review discusses the key challenges and provides future work for constructing DTs of complex engineering systems.

The purpose of this paper is to present a methodology for calculating eddy current losses in the core of a single-phase power voltage transformer, which, unlike a standard power transformer, has an open-type core (I-type core). In those apparatus, reduction of core losses is achieved by using a multipart open-type core that is created by merging a larger number of leaner cores.

3D FEM approach for calculation of eddy current losses in open-type cores based on a weak AλA formulation is presented. Method in which redundant degrees of freedom are eliminated is shown. This enables faster convergence of the simulation. The results are benchmarked using simulations with standard AVA formulation.

Results using weak AλA formulation with elimination of redundant degrees of freedom are in agreement with both simulation using only weak AλA formulation and with simulation based on AVA formulation.

The presented methodology is valid in linear cases, whereas the nonlinear case will be part of future work.

Presented procedure can be used for the optimization when designing the open-type core of apparatus like power voltage transformers.

The presented method is specifically adapted for calculating eddy currents in the open-type core. The method is based on a weak formulation for the magnetic vector potential A and the current vector potential λ, incorporating numerical homogenization and a straightforward elimination of redundant degrees of freedom, resulting in faster convergence of the simulation.

This study aims to provide a comprehensive overview of the current state of the art in powder bed fusion (PBF) techniques for additive manufacturing of multiple materials. It reviews the emerging technologies in PBF multimaterial printing and summarizes the latest simulation approaches for modeling them. The topic of “multimaterial PBF techniques” is still very new, undeveloped, and of interest to academia and industry on many levels.

This is a review paper. The study approach was to carefully search for and investigate notable works and peer-reviewed publications concerning multimaterial three-dimensional printing using PBF techniques. The current methodologies, as well as their advantages and disadvantages, are cross-compared through a systematic review.

The results show that the development of multimaterial PBF techniques is still in its infancy as many fundamental “research” questions have yet to be addressed before production. Experimentation has many limitations and is costly; therefore, modeling and simulation can be very helpful and is, of course, possible; however, it is heavily dependent on the material data and computational power, so it needs further development in future studies.

This work investigates the multimaterial PBF techniques and discusses the novel printing methods with practical examples. Our literature survey revealed that the number of accounts on the predictive modeling of stresses and optimizing laser scan strategies in multimaterial PBF is low with a (very) limited range of applications. To facilitate future developments in this direction, the key information of the simulation efforts and the state-of-the-art computational models of multimaterial PBF are provided.

Transfer relations represent analytical solutions of the linear theory of circular arches, relating each one of the kinematic and static variables at an arbitrary cross-section to the kinematic and static variables at the initial cross-section. The purpose of this paper is to demonstrate the significance of the transfer relations for structural analysis by means of three examples taken from civil engineering.

The first example refers to an arch bridge, the second one to the vault of a metro station and the third one to a real-scale test of a segmental tunnel ring.

The main conclusions drawn from these three examples are as follows: increasing the number of hangers/columns of the investigated arch bridge entails a reduction of the maximum bending moment of the arch, allowing it to approach, as much as possible, the desired thrust-line behavior; compared to the conventional in situ cast method, a combined precast and in situ cast method results in a decrease of the maximum bending moment of an element of the vault of the studied underground station by 46%; and the local behavior of the joints governs both the structural convergences and the bearing capacity of the tested segmental tunnel ring.

The three examples underline that the transfer relations significantly facilitate computer-aided engineering of circular arch structures, including arch bridges, vaults of metro stations and segmental tunnel rings.

Terrestrial laser scanning (TLS) point clouds have been widely used in deformation measurement for structures. However, reliability and accuracy of resulting deformation estimation strongly depends on quality of each step of a workflow, which are not fully addressed. This study aims to give insight error of these steps, and results of the study would be guidelines for a practical community to either develop a new workflow or refine an existing one of deformation estimation based on TLS point clouds. Thus, the main contributions of the paper are investigating point cloud registration error affecting resulting deformation estimation, identifying an appropriate segmentation method used to extract data points of a deformed surface, investigating a methodology to determine an un-deformed or a reference surface for estimating deformation, and proposing a methodology to minimize the impact of outlier, noisy data and/or mixed pixels on deformation estimation.

In practice, the quality of data point clouds and of surface extraction strongly impacts on resulting deformation estimation based on laser scanning point clouds, which can cause an incorrect decision on the state of the structure if uncertainty is available. In an effort to have more comprehensive insight into those impacts, this study addresses four issues: data errors due to data registration from multiple scanning stations (Issue 1), methods used to extract point clouds of structure surfaces (Issue 2), selection of the reference surface S_ref to measure deformation (Issue 3), and available outlier and/or mixed pixels (Issue 4). This investigation demonstrates through estimating deformation of the bridge abutment, building and an oil storage tank.

The study shows that both random sample consensus (RANSAC) and region growing–based methods [a cell-based/voxel-based region growing (CRG/VRG)] can be extracted data points of surfaces, but RANSAC is only applicable for a primary primitive surface (e.g. a plane in this study) subjected to a small deformation (case study 2 and 3) and cannot eliminate mixed pixels. On another hand, CRG and VRG impose a suitable method applied for deformed, free-form surfaces. In addition, in practice, a reference surface of a structure is mostly not available. The use of a fitting plane based on a point cloud of a current surface would cause unrealistic and inaccurate deformation because outlier data points and data points of damaged areas affect an accuracy of the fitting plane. This study would recommend the use of a reference surface determined based on a design concept/specification. A smoothing method with a spatial interval can be effectively minimize, negative impact of outlier, noisy data and/or mixed pixels on deformation estimation.

Due to difficulty in logistics, an independent measurement cannot be established to assess the deformation accuracy based on TLS data point cloud in the case studies of this research. However, common laser scanners using the time-of-flight or phase-shift principle provide point clouds with accuracy in the order of 1–6 mm, while the point clouds of triangulation scanners have sub-millimetre accuracy.

This study aims to give insight error of these steps, and the results of the study would be guidelines for a practical community to either develop a new workflow or refine an existing one of deformation estimation based on TLS point clouds.

The results of this study would provide guidelines for a practical community to either develop a new workflow or refine an existing one of deformation estimation based on TLS point clouds. A low-cost method can be applied for deformation analysis of the structure.

Although a large amount of the studies used laser scanning to measure structure deformation in the last two decades, the methods mainly applied were to measure change between two states (or epochs) of the structure surface and focused on quantifying deformation-based TLS point clouds. Those studies proved that a laser scanner could be an alternative unit to acquire spatial information for deformation monitoring. However, there are still challenges in establishing an appropriate procedure to collect a high quality of point clouds and develop methods to interpret the point clouds to obtain reliable and accurate deformation, when uncertainty, including data quality and reference information, is available. Therefore, this study demonstrates the impact of data quality in a term of point cloud registration error, selected methods for extracting point clouds of surfaces, identifying reference information, and available outlier, noisy data and/or mixed pixels on deformation estimation.

The paper aims to promote the development of intelligent materials and the 4D printing technology by introducing recent advances and applications of additive layered manufacturing (ALM) technology of intelligent materials and the development of the 4D printing technology. Also, an arm-type ALM technology of shape memory polymer (SMP) with thermosetting polyurethane is briefly introduced.

This paper begins with an overview of the development and applications of intelligent materials around the world and the 4D printing technology. Then, the authors provide a brief outline of their research on arm-type ALM technology of SMP with thermosetting polyurethane.

The paper provides the recent developments and applications of intelligent materials and 4D printing technology. Then, it is suggested that intelligent materials mixed with different functional materials will be developed, and these types of materials will be more suitable for 4D printing.

This paper overviews the current developments and applications of intelligent materials and its use in 4D printing technology, and briefly states the authors’ research on arm-type ALM technology of SMP with thermosetting polyurethane.