WIRELY: An all-encompassing universal, scalable, corrective, digital twin for Additive Manufacturing systems

The rise of Industry 4.0 has positioned material extrusion as a central method for advancing Fused Deposition Modeling (FDM) and Additive Manufacturing (AM). Recently, digitalization and Artificial Intelligence have been integrated into FDM and AM 3D-printing workflows, increasing process efficiency while reducing both material consumption and time expenditure. However, current implementations continue to face significant shortcomings in terms of (1) universality, (2) scalability, and (3) closed-loop integration of physical and digital systems. WIRELY directly addresses all three limitations through a pioneering, single-application Digital Twin ecosystem. This architecture leverages the strengths of each dimension, unifying them into a holistic routine designed to elevate both the process and product standards of AM. The universality facet derives from a flexible Unity-based model, with a baseline implementation demonstrated on one of the most widely accessible 3D-printers, while remaining expandable to communicate with broader hardware. Scalability is achieved through a centralized gateway coupled with a multi-functional User Interface capable of managing multiple printers simultaneously. The closed-loop facet integrates a trained Neural Network with a controller to enable automatic, real-time defect detection and correction. This adaptive mirroring of physical and virtual states establishes WIRELY as a comprehensive and corrective framework surpassing conventional, single-focus approaches.