Generative and Predictive AI for digital twin systems in manufacturing

Abstract

The integration of Artificial Intelligence (AI) and Digital Twin (DT) technology is reshaping modern manufacturing by enabling real-time monitoring, predictive maintenance, and intelligent process optimisation. This paper presents the design and partial implementation of an AI-enabled Digital Twin System (AI-DT) for manufacturing, focusing on the deployment of Generative AI (GAI) and Predictive AI (PAI) modules. The GAI component is used to augment training data, perform geometric inspection, and generate 3D virtual testing environments from multiview video input. Meanwhile, PAI leverages sensor data to enable proactive defect detection and predictive quality analysis in welding processes. These integrated capabilities significantly enhance the system's ability to anticipate issues and support decision-making. While the framework also envisions incorporating Explainable AI (EAI), Context-Aware AI (CAI), and Agentic AI (AAI) for future extensions, the current work establishes a robust foundation for scalable, intelligent digital twin systems in smart manufacturing. Our findings contribute toward improving operational efficiency, quality assurance, and early-stage digital-physical convergence.