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Digital twin ushers in growth as one cutting-edge technology that enables high-precision, informative and real-time interaction of advanced composites, influencing the paradigm of composite analysis and design in aerospace, automotive, intelligent electronics and other fields. The online and fine evolution of digital twins at scale face challenges due to creating scalable predictions, updates, and controls with coupled information in workflows. In this work, an interactive digital twin methodology for complex composite structures (CCSDT) based on machine learning is introduced. To demonstrate the framework's feasibility and applicability, a hybrid architecture comprising hierarchical deep neural networks (H-DNNs), statistical inference and cross-scale physical constraints is proposed considering the fabric rubber composites (FRC) in aerospace field. The framework predicts 3D displacement and stress fields directly from sensing features and can incorporate dynamic updating and evaluation of computational models into data assimilation. Real-time prediction and uncertainty quantification are verified through synthetic and experimental data, and the capability of CCSDT in perception and decision is demonstrated by a case of cruise state monitoring. The comparison between the measured strain field and the post-processing predicted strain field shows the extensibility of the direct prediction results. These results provide guidance for the development of composite digital twins, stimulating the potential for cost-effective and efficient digital twin services. [Display omitted] [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]