Real-Time Models for Manufacturing Processes: How to Build Predictive Reduced Models

New data science and real-time modeling techniques facilitate better monitoring and control of manufacturing processes. By using real-time data models, industries can improve their processes and identify areas where resources are being wasted. Despite the challenges associated with implementing these data models in transient and multi-physical processes, they can significantly optimize operations, reduce trial and error, and minimize the overall environmental footprint. Implementing real-time data analytics allows industries to make quicker, informed decisions and immediate corrections to material processes. This ensures that manufacturing sustainability targets are regularly met and product quality is maintained. New concepts such as digital twins and digital shadows have been developed to bridge the gap between physical manufacturing processes and their virtual counterparts. These virtual models can be continuously updated with data from their physical counterparts, enabling real-time monitoring, control, and optimization of manufacturing processes. This paper demonstrates the predictive power of real-time reduced models within the digital twin framework to optimize process parameters using data-driven and hybrid techniques. Various reduced and real-time model-building techniques are investigated, with brief descriptions of their mathematical and analytical foundations. The role of machine learning (ML) and ML-assisted data schemes in enhancing predictions and corrections is also explored. Real-world applications of these reduced techniques for extrusion and additive manufacturing (AM) processes are presented as case studies.