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International Journal of Science, Strategic Management and Technology

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ISSN: 3108-1762 (Online)
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DIGITAL TWIN TECHNOLOGY IN ELECTRONICS ENABLING INTELLIGENT DESIGN, SMART MANUFACTURING, AND PREDICTIVE MAINTENANCE

AUTHORS:
Malloju Dushyanthachary
Edla Chandu
Mentor
N Swaroop
Affiliation
Department Of ECE, SVS Group of Institutions, Hanmakonda, Telangana
CC BY 4.0 License:
This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution (CC BY) license, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.
Abstract
Digital Twin (DT) technology has emerged as a transformative paradigm in the electronics industry by enabling the creation of real-time virtual replicas of physical electronic systems, devices, and manufacturing processes. The integration of Internet of Things (IoT) sensors, artificial intelligence (AI), machine learning (ML), cloud computing, and edge computing facilitates continuous synchronization between physical assets and their digital counterparts, allowing real-time monitoring, predictive analysis, fault diagnosis, and performance optimization. In electronics design and manufacturing, Digital Twins improve production efficiency by detecting defects at early stages, optimizing process parameters, reducing equipment downtime, and enhancing product quality through predictive maintenance and intelligent decision-making. Furthermore, DT technology supports lifecycle management by enabling virtual testing, design validation, thermal analysis, reliability assessment, and energy optimization before physical deployment, thereby minimizing development costs and shortening time-to-market. The incorporation of advanced data analytics and simulation models also enables adaptive manufacturing, supply chain optimization, and sustainable electronics production. Despite these advantages, several challenges remain, including high computational requirements, interoperability among heterogeneous systems, cybersecurity risks, data privacy concerns, and the need for standardized communication frameworks. This paper presents a comprehensive overview of Digital Twin technology in electronics, discussing its architecture, enabling technologies, applications, benefits, and current research challenges. The study also highlights future research directions involving AI-driven autonomous Digital Twins, federated learning, blockchain-enabled secure data sharing, explainable artificial intelligence, and next-generation intelligent electronic systems for Industry 5.0. The findings demonstrate that Digital Twin technology has significant potential to revolutionize electronic system design, manufacturing, maintenance, and lifecycle management through intelligent, data-driven, and autonomous operations.

 

 
Keywords
Digital Twin Electronics Manufacturing Internet of Things (IoT) Artificial Intelligence Machine Learning Predictive Maintenance Edge Computing Cloud Computing Smart Manufacturing Industry 5.0 Cyber-Physical Systems Real-Time Monitoring.
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Dushyanthachary, M. & Chandu, E. (2026). Digital Twin Technology in Electronics Enabling Intelligent Design, Smart Manufacturing, and Predictive Maintenance. International Journal of Science, Strategic Management and Technology, 02(7), 1-9. https://doi.org/10.55041/ijsmt.v2i7.102

Dushyanthachary, Malloju, and Edla Chandu. "Digital Twin Technology in Electronics Enabling Intelligent Design, Smart Manufacturing, and Predictive Maintenance." International Journal of Science, Strategic Management and Technology, vol. 02, no. 7, 2026, pp. 1-9. doi:https://doi.org/10.55041/ijsmt.v2i7.102.

Dushyanthachary, Malloju, and Edla Chandu. "Digital Twin Technology in Electronics Enabling Intelligent Design, Smart Manufacturing, and Predictive Maintenance." International Journal of Science, Strategic Management and Technology 02, no. 7 (2026): 1-9. https://doi.org/https://doi.org/10.55041/ijsmt.v2i7.102.

References

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  2. Fu, Y., Zhu, G., Zhu, M., & Xuan, F. (2022). Digital twin for integration of design-manufacturing-maintenance: an overview. Chinese Journal of Mechanical Engineering35(1), 80.

  3. Tao, F., Zhang, M., & Nee, A. Y. C. (2019). Digital twin driven smart manufacturing. Academic press.

  4. Falekas, G., & Karlis, A. (2021). Digital twin in electrical machine control and predictive maintenance: State-of-the-art and future prospects. Energies14(18), 5933.

  5. Yakhni, M. F., Hosni, H., Cauet, S., Sakout, A., Etien, E., Rambault, L., ... & El-Gohary, M. (2022). Design of a digital twin for an industrial vacuum process: a predictive maintenance approach. Machines10(8), 686.

  6. He, B., & Bai, K. J. (2021). Digital twin-based sustainable intelligent manufacturing: a review. Advances in Manufacturing9(1), 1-21.

  7. Zhong, D., Xia, Z., Zhu, Y., & Duan, J. (2023). Overview of predictive maintenance based on digital twin technology. Heliyon9(4).

  8. Xia, K., Sacco, C., Kirkpatrick, M., Saidy, C., Nguyen, L., Kircaliali, A., & Harik, R. (2021). A digital twin to train deep reinforcement learning agent for smart manufacturing plants: Environment, interfaces and intelligence. Journal of Manufacturing Systems58, 210-230.

  9. Abdullahi, I., Longo, S., & Samie, M. (2024). Towards a distributed digital twin framework for predictive maintenance in industrial internet of things (IIoT). Sensors24(8), 2663.

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This article has undergone plagiarism screening and double-blind peer review. Editorial policies have been followed. Authors retain copyright under CC BY-NC 4.0 license. The research complies with ethical standards and institutional guidelines.
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