Digital Twins as an Emerging Solution in AI-Driven Modeling and Metrology of Industry 5.0/6.0 Production Systems

Article discusses Digital Twins (DTs) as a solution for artificial intelligence (AI)-based modeling and metrology in Industry 5.0 and Industry 6.0 manufacturing systems. DTs enable the creation of real-time virtual replicas of physical assets, processes, and systems, increasing transparency, prediction, and optimization in manufacturing environments. By integrating AI, machine learning (ML), and advanced sensor data, DT support adaptive, self-learning production models capable of responding to dynamic operating conditions. In metrology, DTs improve measurement accuracy, traceability, and quality assurance by continuously synchronizing data between the physical and virtual domains. This technology improves process simulation, predictive maintenance, and fault detection, reducing downtime and operating costs. Furthermore, DTs facilitate human-centric production by enabling collaborative decision-making between intelligent systems and skilled workers. Their role in sustainable production is significant, supporting energy optimization, waste reduction, and lifecycle performance analysis. In Industry 6.0, DTs go beyond cyber-physical integration to encompass cognitive intelligence, ethical automation, and autonomous optimization. However, challenges remain in data interoperability, cybersecurity, model scalability, and real-time computational performance. DTs represent a revolutionary framework for the development of intelligent, resilient, and precise manufacturing ecosystems in next-generation industrial systems.