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Research Area

AI-Enabled Digital Twins for
Real-Time Decision-Making

We develop digital twin frameworks that fuse physics-based models with machine learning to enable real-time monitoring, control, and uncertainty-aware decision-making throughout a system's lifecycle.

AI-Enabled Digital Twin framework

Overview

Digital twins — virtual replicas of physical systems that continuously synchronize with real-world counterparts through sensor data — represent a transformative paradigm in engineering. Our research advances this paradigm by embedding AI and machine learning directly into the digital twin framework, enabling autonomous, real-time decision-making under uncertainty.

We address three core challenges: (1) building computationally efficient surrogate models that operate at control-loop speeds; (2) quantifying and propagating uncertainty through model predictions; and (3) closing the loop between prediction and action through advanced control strategies such as Model Predictive Control (MPC) and Reinforcement Learning (RL).

Application domains include additive manufacturing, full-vehicle active suspension systems, and broader autonomous engineering systems where real-time adaptation and lifecycle management are critical.

Key Research Themes

Physics-Informed Surrogate Models

We develop time-series deep neural networks and neural operators that learn from high-fidelity simulations and sensor data to emulate complex system dynamics at real-time speeds.

Uncertainty-Aware Control

We quantify model uncertainty using Bayesian inference and deep quantile learning, then propagate it into robust control policies (e.g., Tube-MPC) that maintain constraint satisfaction under noise and model error.

Lifecycle Adaptation

We design digital twin architectures that support iterative learning and re-optimization across system generations, enabling systems that improve continuously over their operational lifetime.

Selected work

Related Publications

Full vehicle active suspension system
Digital Twin 2026

Reinforcement learning-based control co-design of digital twin-enabled full-vehicle active suspension systems

Ying-Kuan Tsai, Yi-Ping Chen, Vispi Karkaria, Wei Chen

Structural and Multidisciplinary Optimization · April 2026

Digital Twin CCD RL animation
CCD 2026

Digital Twin-Enabled Multi-Generation Control Co-Design with Deep Reinforcement Learning

Ying-Kuan Tsai, Vispi Karkaria, Yi-Ping Chen, Wei Chen

Journal of Mechanical Design · Accepted 2026

Uncertainty-aware digital twin concept
Digital Twin 2026

Uncertainty-Aware Digital Twins: Robust Model Predictive Control Using Time-Series Deep Quantile Learning

Yi-Ping Chen, Ying-Kuan Tsai, Vispi Karkaria, Wei Chen

Journal of Mechanical Design · February 2026

MPC additive manufacturing animation
Digital Twin 2026

Real-Time Decision-Making for Digital Twin in Additive Manufacturing with Model Predictive Control Using Time-Series Deep Neural Networks

Yi-Ping Chen, Vispi Karkaria, Ying-Kuan Tsai, Faith Rolark, Daniel Quispe, Robert X Gao, Jian Cao, Wei Chen

Journal of Manufacturing Systems · August 2026

Digital twin framework
Optimization 2025

An Optimization-Centric Review on Integrating Artificial Intelligence and Digital Twin Technologies in Manufacturing

Vispi Karkaria, Ying-Kuan Tsai, Yi-Ping Chen, Wei Chen

Engineering Optimization · January 2025

Roadmap on AI and ML for smart manufacturing digital twin
Digital Twin 2026

Physics-Based Predictive Control and Real-Time Decision-Making for Digital Twin–Enabled Autonomous Manufacturing

Wei Chen, Vispi Karkaria, Yi-Ping Chen, Ying-Kuan Tsai

In Roadmap on AI and ML for Smart Manufacturing, ed. Jay Lee (Machine Learning: Engineering) · March 2026

Adaptive digital twin of sheet metal forming
Digital Twin 2026

Adaptive Digital Twin of Sheet Metal Forming via Proper Orthogonal Decomposition-Based Koopman Operator with Model Predictive Control

Yi-Ping Chen, Derick Suarez, Ying-Kuan Tsai, Vispi Karkaria, Guanzhong Hu, Zihan Chen, Ping Guo, Jian Cao, Wei Chen

Journal of Manufacturing Systems · June 2026