Research library / 2025 / Review article
AI-enhanced digital twins in maintenance: Systematic review, industrial challenges, and bridging research–practice gaps
Journal of Manufacturing Systems · 2025
Abstract
Original English abstract
The convergence of artificial intelligence (AI) and digital twin technology is reshaping maintenance strategies in the era of Industry 4.0. However, gaps persist between academic advancements and industrial adoption and expectation. This study systematically investigates the landscape of AI-enhanced digital twins for maintenance by integrating a systematic literature review (SLR) of related studies with in-depth interviews from industry practitioners. Our analysis reveals that while academia demonstrates robust applications of supervised, deep, and reinforcement learning to optimize digital twin models and prescribe data-driven actions, industrial implementation remains limited by challenges such as high scale dimension, data integration complexities, and insufficient workforce readiness. We identified and articulated three critical gap dimensions, scale, data, and model between academic research and industrial implementation and expectation. To bridge these gaps, we proposed a comprehensive five-layer framework for AI-enhanced digital twins, encompassing physical assets, data transmission, digital twins, AI analytics, and maintenance services. Actionable recommendations are provided, including the adoption of modular architectures, standardized data protocols, hybrid edge-cloud solutions, and targeted workforce upskilling. Our findings not only clarify the current state and challenges of AI-driven digital twins in maintenance but also offer a practical roadmap for accelerating their industrial implementation. This work advances the field by integrating insights from both academic research and industrial practice, offering concrete recommendations to support the practical realization of smart and sustainable maintenance practices.
Original source: Chalmers Research ↗
In brief
This review combines published research with industry interviews to examine AI-enhanced digital twins in maintenance. It identifies gaps between research and industrial practice and proposes a five-layer implementation framework.
Key points
- Identifies gaps in scale, data and models between academic research and industrial practice.
- Connects physical assets, data transmission, digital twins, AI analytics and maintenance services in a five-layer framework.
- Recommends modular architectures, standardized data protocols and workforce upskilling.
Cite this work
Siyuan Chen, Ebru Turanoglu Bekar, Jon Bokrantz, Anders Skoogh (2025). AI-enhanced digital twins in maintenance: Systematic review, industrial challenges, and bridging research–practice gaps. Journal of Manufacturing Systems, 82, pp. 678–699. https://doi.org/10.1016/j.jmsy.2025.07.006
@article{Chen2025AiDigitalTwins,
title = {{AI-enhanced digital twins in maintenance: Systematic review, industrial challenges, and bridging research–practice gaps}},
author = {Chen, Siyuan and Turanoglu Bekar, Ebru and Bokrantz, Jon and Skoogh, Anders},
year = {2025},
journal = {Journal of Manufacturing Systems},
volume = {82},
pages = {678--699},
doi = {10.1016/j.jmsy.2025.07.006},
url = {https://research.chalmers.se/en/publication/547714}
}
Abstract reproduced from the linked source record. The overview and key points are concise explanations of the study.