White Paper: Scalable Digital Twin Capabilities for Aging and Surveillance of Engineered Systems

Technical Report · Fri Nov 14 04:00:00 EST 2025

DOI:https://doi.org/10.2172/3001797· OSTI ID:3001797

Boyle, Mike ^[1]

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1. Lawrence Livermore National Laboratory (LLNL), Livermore, CA (United States)

This white paper presents a multi-year initiative to develop practical, secure, and scalable digital twin capabilities for engineered systems in aging and surveillance contexts—an approach pioneered at the National Nuclear Security Administration (NNSA) Lawrence Livermore National Laboratory (LLNL) that maps directly onto the needs and ambitions of the Navy for ship- and fleet-level digital twins. LLNL’s work in building part- and process-level digital twins for advanced manufacturing, with a vision to scale up to entire factory floors and, ultimately, enterprise-wide digital twins, offers an adaptable pathway for the Navy as it seeks to modernize lifecycle management, readiness, and predictive maintenance across ships and fleets. For our application, we integrate physics-based modeling with automated data ingestion, processing, and AI-driven calibration, creating hybrid models that are both interpretable and data responsive. We modernized legacy workflows, established centralized data infrastructure, automated experimental pipelines, and demonstrated end-to-end coupling of accelerated aging data with finite element simulations via optimization and surrogate modeling. The result is a generalizable framework that supports part-level digital twins today and lays the groundwork for future system-level twins suitable for Navy applications.

• Research Organization: Lawrence Livermore National Laboratory (LLNL), Livermore, CA (United States)
• Sponsoring Organization: USDOE National Nuclear Security Administration (NNSA)
• DOE Contract Number: AC52-07NA27344
• OSTI ID: 3001797
• Report Number(s): LLNL--TR-2013372
• Country of Publication: United States
• Language: English

Related Subjects

42 ENGINEERING
Computer science
Engineering
Materials science