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The meticulous reconstruction of three-dimensional (3D) braided composite materials serves as a crucial foundation for achieving high-fidelity simulations. Nonetheless, the transition from tomographic images to a 3D mesh entails a laborious and time-intensive process. To address this, an integrated procedure based on artificial intelligence is proposed for reconstructing meshes from tomograms. The initial stage of the process involves employing artificial intelligence techniques to segment complex contours and optimize high-dimensional contours. This facilitates the input of high-quality images needed to reconstruct accurate digital twins with strong convergence. The subsequent reconstruction phase integrates various calculations, including shape interpolation, contour extraction, 3D surface reconstruction, 3D mesh reconstruction, and element data interpolation. During this process, optimization objectives are set to minimize the deviation between the digital twin's surface and the actual surface, as well as to optimize the aspect ratio of the element mesh. Upon completion of the aforementioned steps, high-quality input files suitable for finite element calculations are directly generated. Ultimately, the proposed method utilizes the reconstructed finite element model for mechanical analysis, and the results are found to be in good agreement with experimental tests. This method offers an efficient and rapid way to achieve high-quality reconstruction of complex digital twins. [Display omitted] • The proposed procedure to reconstruct meshes from tomograms is integrated, enabling batch processing. • The deep learning models are employed to segment the intricate yarns contours of 3D5D braided composites. • The Ramer–Douglas–Peucker algorithm is used to capture high-dimensional contour features and improve convergence. • A decimating filter employing the quadric-based edge-collapsed strategy improves volumetric meshing. [ABSTRACT FROM AUTHOR]

Digital twins are undergoing growth that enables highly informative and scaleable interaction between physical objects and virtual twins, which is of great significance to the life cycle analysis of composites. Real-time fine evolution is challenging due to vast combinations of input features and high-resolution calculated variables. Here, we systematically demonstrate an AI-based methodology for digital twinning of complex composite structures. First, three types of deep neural networks are created with optionally used autoencoders as surrogate models, with architectures and data processing inspired by the rule-of-mixture of composites. Second, the prediction accuracy and efficiency are evaluated quantitatively and qualitatively, demonstrating the feasibility of predicting 3D displacement and stress fields directly from sensing data of temperature, pressure and loading displacement, and the optimal architecture is selected to be the evolving digital twin. Finally, the real-time interactive experiments are relayed to the digital twin and demonstrated that it can interact with physical objects and evolve online with high accuracy. These results indicate that the computational time can be reduced by 3∼6 orders of magnitude with high information intensity and scalability compared with conventional numerical and experimental methods, which opens up the avenues for the cost-effective and efficient development of digital twin services for composites. [Display omitted] [ABSTRACT FROM AUTHOR]