Twinning the future: Implementing digital twin technology in the optimisation of fibre-reinforced polymers

Optimisation of fibre-reinforced polymers (FRPs) is critical for engineering a sustainable future. This review paper explores the potential of digital twins (DTs) in enhancing the characteristics, performance, and sustainability of synthetic and sustainable FRPs. DTs provide a virtual space for real-time monitoring and predictive analysis and have revolutionised the traditional limitations of FRP production. Recent case studies, like the FASTIGUE project and advances in fibre-reinforced thermoplastics, showcase the DT’s powerful role in addressing issues during production. The paper also discusses the unique challenges of developing sustainable “green” composites that balance performance with biodegradability to meet the Sustainable Development Goals. It highlights the benefits of utilising DTs to scrutinise the manufacturing processes of both synthetic and natural FRPs. Modern DTs have demonstrated the capacity to optimise the curing kinetics and mechanical properties of these materials. Furthermore, case studies such as the 3D-printed continuous carbon fibre composites, overmoulded fibre-reinforced thermoplastics, and recyclable Elium®-based composites authenticate the capabilities of DTs in enhancing the sustainable manufacturing of FRPs. Acknowledging future challenges, the paper recommends integrating production and sustainability metrics into modern multi-tier DT systems for holistic benefits.