Fabrication Method Research Articles

Current Advances and Future Directions of Pluripotent Stem Cells-Derived Engineered Heart Tissue for Treatment of Cardiovascular Diseases

Cardiovascular diseases resulting from myocardial infarction (MI) remain a leading cause of death worldwide, imposing a substantial burden on global health systems. Current MI treatments, primarily pharmacological and surgical, do not regenerate lost myocardium, leaving patients at high risk for heart failure. Engineered heart tissue (EHT) offers a promising solution for MI and related cardiac conditions by replenishing myocardial loss. However, challenges like immune rejection, inadequate vascularization, limited mechanical strength, and incomplete tissue maturation hinder clinical application. The discovery of human-induced pluripotent stem cells (hiPSCs) has transformed the EHT field, enabling new bioengineering innovations. This review explores recent advancements and future directions in hiPSC-derived EHTs, focusing on innovative materials and fabrication methods like bioprinting and decellularization, and assessing their therapeutic potential through preclinical and clinical studies. Achieving functional integration of EHTs in the heart remains challenging due to the need for synchronized contraction, sufficient vascularization, and mechanical compatibility. Solutions such as genome editing, personalized medicine, and AI technologies offer promising strategies to address these translational barriers. Beyond MI, EHTs also show potential in treating ischemic cardiomyopathy, heart valve engineering, and drug screening, underscoring their promise in cardiovascular regenerative medicine.

Multiphase Janus Azobenzene Inverse Opal Membrane toward On-Demand Photocontrolled Motion.

Azobenzene actuators have generated extensive research investment in the field of soft robots, artificial muscles, etc., based on the typical photoresponsive trans-cis isomerization. However, it remains challenging to achieve multiphase actuation at the gas-liquid interface and liquid phase. To solve these problems, this paper demonstrated a simple fabrication method of a Janus azobenzene inverse opal membrane with one side having a polydomain azobenzene inverse opal structure and the other side having a monodomain bulk azobenzene polymer. The introduction of an inverse opal structure increases the interaction area between the liquid and polymer network. The proposed design can freely swim in any direction at the air-liquid interface based on the Marangoni effect or move forward in the liquid phase based on bubble propulsion under UV irradiation. This work is of great significance for the design and fabrication of multiphase photo actuators.

UV Irradiation as a Versatile Low-Temperature Strategy for Fabricating Templated Mesoporous Titania Films.

Mesoporous titania thin films offer promising applications in sensors, batteries, and solar cells. The traditional soft templating methods rely on high-temperature calcination, which is energy-intensive, incompatible with thermosensitive flexible substrates, and destructive for titania structures. This work demonstrates UV irradiation as a versatile low-temperature and energy-saving alternative for mesoporous crystalline titania fabrication. Grazing incidence wide-angle X-ray scattering analysis reveals a three-stage crystallization process with increasing UV irradiation time supported by photoluminescence data. UV-irradiation-derived samples exhibit crystallinity and crystal size comparable to that of calcination. Integration with block copolymer templated sol-gel synthesis enables the creation of various morphologies, including cylindrical, ordered spherical, and hybrid structures. Characterizations via scanning electron microscopy and grazing incidence small-angle X-ray scattering confirm the homogeneity of morphology in the resulting films. The resulting films maintain similar optical properties despite morphological differences, as demonstrated by photoluminescence and UV-vis measurements. The versatility of UV irradiation extends to different titanium precursors, underscoring it as a flexible and efficient method for mesoporous titania thin film fabrication at low temperatures.

Analysis of Microstructure and Mechanical Properties of CoCrMo Alloys Processed by Metal Binder Jetting Multi-Step Technique

Metal Binder Jetting (BJT/M) has emerged as a promising additive manufacturing (AM) technology for the realization of complex parts using a wide range of metal alloys. This technology offers several advantages, such as design flexibility, reduced lead times, a high building rate, and the ability to fabricate intricate geometries that are difficult or impossible to achieve with conventional manufacturing methods. Cobalt Chromium Molybdenum (CoCrMo) alloys are particularly suitable for demanding applications in the aerospace, biomedical, and industrial sectors that require high strength and hardness, corrosion resistance, and biocompatibility. In this work, ten cubic and ten tensile samples were printed with a layer height of 50 µm using the shell printing method, debound and sintered at 1325 °C for 4 h, with the aim of investigating the properties of CoCrMo parts made using BJT technology. A density of 7.88 g/cc was obtained from the Archimede’s test. According to the printing and sintering parameters, an average hardness of 18.5 ± 1.8 HRC and an ultimate tensile strength of 520.5 ± 44.6 MPa were obtained. Finally, through a microstructure analysis, an average grain size of 182 ± 14.7 µm was measured and the presence of an intergranular Cr-rich phase and Mo-rich carbides was detected.

Rehabilitation of eviscerated missing eye with customised heat cure acrylic ocular prosthesis: A case report with a follow-up period of 6 years

Ocular prosthesis refers to a specialized medical device designed to replace a missing or damaged eye. These prostheses are custom-made to fit the individual's unique anatomy and are primarily used for cosmetic purposes, though they can also help in maintaining the natural shape of the eye socket and supporting surrounding tissue. This article describes a case of rehabilitation of the missing right eye due to evisceration by a customized ocular prosthesis with a follow-up period of six years and gives a brief description of the method of processing, centration and fabrication. Acrylic customised ocular prosthesis for the rehabilitation of the eviscerated eye reported higher patient acceptance and satisfaction due to the lifelike appearance of the prosthesis.

INFLUENCE OF ADDITIVE MANUFACTURING TECHNOLOGY OF TOPOLOGICALLY OPTIMIZED PRODUCTS FROM PHOTOPOLYMER RESINS ON THE ANISOTROPY OF THEIR MECHANICAL PROPERTIES

This article discusses the problem of ensuring strength and minimum mass in the design of products manufactured using additive technologies. The authors investigated the possibility of using topological optimization in computer-aided design systems to create an optimized model with the necessary strength at a minimum weight. As part of the work, the topological optimization of the bracket, the production of its samples by additive manufacturing methods and strength tests were carried out. The optimal values were found via finite element analysis using the SolidWorks and ANSYS software. The calculation results show that the optimized model retains about 20% of the original mass and has the necessary mechanical characteristics. In particular, the excess safety margin is reduced by 2.5 times, which is acceptable for this bracket. The subsequent verification of the models is carried out through destruction tests of the products manufactured using additive technologies, i.e. the method of filament deposition and stereolithography. To account for the anisotropy of the material, a series of samples oriented at different angles to the direction of construction was made. The tests were carried out on a test bench for simultaneous biaxial stretching, which corresponds to the design loads on the bracket. An increase in the tensile load on the sample was carried out before its destruction. In the course of the work, the presence of anisotropy of mechanical properties was revealed, and optimization results in various software packages were studied. The results of strength tests allow us to draw two conclusions. Firstly, due to the anisotropy of the material, the strength properties significantly depend on the orientation of the bracket during additive manufacturing. Secondly, the bracket, optimized by means of the SolidWorks software package, generally showed the best strength properties for various orientations during manufacturing. Also, which is quite expected, the samples obtained by stereolithography showed less anisotropy than the samples obtained by the method of filament deposition. In conclusion, it is noted that the use of additive technologies to create optimized forms requires considering printing technologies and anisotropy of properties, as well as the choice of appropriate software.

Protein and Polysaccharide Fibers via Air Jet Spinning: Emerging Techniques for Biomedical and Sustainable Applications

Polymers play a critical role in the biomedical and sustainable materials fields, serving as key resources for both research and product development. While synthetic and natural polymers are both widely used, synthetic polymers have traditionally dominated due to their ability to meet the specific material requirements of most fiber fabrication methods. However, synthetic polymers are derived from non-renewable resources, and their production raises environmental and health concerns. Natural polymers, on the other hand, are derived from renewable biological sources and include a subset known as biopolymers, such as proteins and polysaccharides, which are produced by living organisms. These biopolymers are naturally abundant and offer benefits such as biodegradability and non-toxicity, making them especially suitable for biomedical and green applications. Recently, air jet spinning has emerged as a promising method for fabricating biopolymer fibers, valued for its simplicity, cost-effectiveness, and safety—advantages that stand out compared to the more conventional electrospinning process. This review examines the methods and mechanisms of air jet spinning, drawing on empirical studies and practical insights to highlight its advantages over traditional fiber production techniques. By assembling natural biopolymers into micro- and nanofibers, this novel fabrication method demonstrates strong potential for targeted applications, including tissue engineering, drug delivery, air filtration, food packaging, and biosensing, utilizing various protein and polysaccharide sources.

THE INFLUENCE OF REVERSE GEOMETRIC MODELING TO THE DIMENSIONS AND SHAPE OF THE 3D MODEL

The aim of the study is to investigate the effect of point reduction on the dimensions of a part produced by two different additive technologies, Stereolithography (SLA) and Fused Deposition Modelling (FDM). Also, the effect of polygonization methods on the number of points and file size. For the purpose of the experiment, a part was fabricated which was made up of geometric elements, which served to investigate the influence of the reverse geometric modelling on parameter variation. Subsequently, the model was made into two samples by additive manufacturing FDM and SLA on Stratasys F370 (FDM) and Form 3 (SLA). From the fabricated samples, 3D data was collected on a Metrotom industrial CT 1500, cloud of points was obtained and polygonised in various ways in CAQ software GOM Inspect and CARE software VG Studio MAX. The evaluation as well as the process reverse modelling was performed in Autodesk Powershape software. The results show that different polygonization methods affect the number of polygonal mesh points and the volume of data. It was also found that the reduction of the points by which the polygonal network is formed leads to variations in the dimensions of the geometric features. Another important factor is the method of additive manufacturing of the component, where we have shown point reduction has a different effect for a component manufactured by SLA and a component manufactured by FDM.

Continuous natural fiber-reinforced shape memory polymer biocomposites: Design and fabrication for sustainable self-folding architectural applications

Abstract The growing demand for sustainable building materials has driven the search for innovative solutions that minimize environmental impact while enhancing architectural functionality. Nature’s adaptability to environmental changes, such as the mimosa plant’s sensitivity to temperature and touch, has inspired the development of shape memory materials like shape memory polymers (SMPs). These materials change shape in response to external stimuli, offering promising solutions for responsive and eco-friendly applications. This study investigates the use of SMP biocomposites (SMPBCs) reinforced with continuous flax fibers for sustainable architectural applications. The main aim is to enhance the mechanical and shape memory properties of these materials, focusing on design exploration, fabrication methods, and performance evaluation for architectural use. Combining material science with digital fabrication techniques, particularly Tailored Fiber Placement (TFP), this research integrates flax fiber into thermo-responsive epoxy-based SMPs. Origami-inspired designs, including rigid and curved folding origami, were explored using a moldless fabrication technique to optimize the SMPBCs’ performance and facilitate the creation of complex three-dimensional structures. The study began with initial prototypes of simple origami shapes, followed by three architectural prototypes representing distinct origami types. Curved folding origami enhances shape memory performance by enabling larger deformation, which increases strain energy storage and allows more effective recovery. Further exploration of Single and Multi Degree of Freedom (SDOF and MDOF) designs for architectural applications revealed that curved SDOF prototypes achieved the highest shape recovery ratio (Rr%) of 97%, while rigid MDOF prototypes showed the lowest Rr of 60% and 70%. All prototypes provided a high shape fixity ratio of nearly 100%. Moreover, initial load tests on the permanent shapes demonstrated their ability to support over 240 times their weight. This research advances sustainable architecture by showing how SMPBCs with optimal geometric designs can enable self-shaping and multifunctional applications, paving the way for more adaptive, eco-friendly building materials.

Electrically controlled flexible and varifocal microlens array using liquid crystals on polymer

Abstract The microlens array (MLA) on the flexible substrates has a wide range of applications in advancing curved integral imaging and three-dimensional (3D) display systems with a large field of view. We developed an electrically controlled varifocal microlens array on flexible Polyethylene Terephthalate (PET) substrates by infiltrating the liquid crystals (LC) in polymeric concave lenses. The focusing and imaging characteristics of the flexible LC-MLA are studied experimentally. When voltage is applied across the LC layer, the refractive index of the LC changes, which causes a change in the effective focal length of MLA. The electrically tunable focal length and tunable focusing of the MLA are experimentally demonstrated. The mathematical analysis of the LC MLA is performed using the MATLAB platform. The presented flexible LC-MLA is developed using simple and cost-effective fabrication methods, which can potentially be used in future 3D displays and imaging solutions.

Enhance Photo-Stability of Up-Scalable Organic Solar Cells: Suppressing Radical Generation in Polymer Donors.

The power conversion efficiency (PCE) of single-junction organic solar cells (OSCs) has been promoted above 20%. Device up-scaling draws more and more research attentions. Besides the high PCE for devices with up-scalable fabrication methods and conditions, achieving high stability simultaneously is essential for pushing industrialization of this technology. Here, the stability of the state-of-the-art OSCs blade-coated in air with non-halogenated solvents in a wide thickness range is thoroughly investigated. The losses in short-circuit current density under photo-thermal stress strongly depend on processing conditions. Devices with less crystalline phases in unit thickness show faster generation of trap states and hence strongly reduced charge collection efficiency. Through in-depth photo-chemical, photo-physical, and morphological characterizations during ageing, faster generation of radicals in PM6 for active layers with more amorphous structures is identified as the cause for device degradation. Increasing the crystallinity of active layer films for suppressing radical generation in polymer donors is critical to enhance the photo-thermal stability of devices processed in air with a wide thickness range.

Advances in Research of Hydrogel Microneedle-Based Delivery Systems for Disease Treatment

Microneedles (MNs), composed of multiple micron-scale needle-like structures attached to a base, offer a minimally invasive approach for transdermal drug delivery by penetrating the stratum corneum and delivering therapeutic agents directly to the epidermis or dermis. Hydrogel microneedles (HMNs) stand out among various MN types due to their excellent biocompatibility, high drug-loading capacity, and tunable drug-release properties. This review systematically examines the matrix materials and fabrication methods of HMN systems, highlighting advancements in natural and synthetic polymers, and explores their applications in treating conditions such as wound healing, hair loss, cardiovascular diseases, and cancer. Furthermore, the potential of HMNs for disease diagnostics is discussed. The review identifies key challenges, including limited mechanical strength, drug-loading efficiency, and lack of standardization, while proposing strategies to overcome these issues. With the integration of intelligent design and enhanced control over drug dosage and safety, HMNs are poised to revolutionize transdermal drug delivery and expand their applications in personalized medicine.

Beyond Smoothness: The Art of Surface Texturing Battling against Friction

Abstract Leveraging surface texturing to realize significant friction reduction at contact interfaces has emerged as a preferred technique among tribology experts, boosting tribological energy efficiency and sustainability. This review systematically demonstrates optimization strategies, advanced manufacturing methods, typical applications, and outlooks of technical challenges toward surface texturing for friction reduction. Firstly, the lubricated contact models of microtextures are introduced. Then, we provide a framework of state-of-the-art research on synergistic friction optimization strategies of microtexture structures, surface treatments, liquid lubricants, and external energy fields. A comparative analysis evaluates the strengths and weaknesses of manufacturing techniques commonly employed for microtextured surfaces. The latest research advancements in microtextures in different application scenarios are highlighted. Finally, the challenges and directions of future research on surface texturing technology are briefly addressed. This review aims to elaborate on the worldwide progress in the optimization, manufacturing, and application of microtexture-enabled friction reduction technologies to promote their practical utilizations.

Оценка качества и механических свойств получаемых слоев металла из низкоуглеродистой стали методом WAAM с использованием дополнительной механической и ультразвуковой обработки

Introduction. Additive manufacturing is a technology that enables three-dimensional (3D) components to be printed layer by layer according to digital models. Completely different from traditional manufacturing methods such as casting, forging, and machining, additive manufacturing is a near net shape manufacturing process that can greatly enhance design freedom and reduce manufacturing runtime. The material processing challenges in Wire and Arc Additive Manufacturing (WAAM) are related to achieving performance metrics related to geometric, physical, and material properties. Tight tolerances and stringent surface integrity requirements cannot be achieved by utilizing stand-alone AM technologies. Therefore, WAAM parts typically require some post-processing to meet requirements related to surface finish, dimensional tolerances and mechanical properties. It is therefore not surprising that the integration of AM with post-processing technologies into single and multi-setup machining solutions, commonly referred to as hybrid AM, has become a very attractive proposition for industry. The purpose of the work is to evaluate the quality and mechanical properties of the resulting metal layers of mild steel by WAAM method using additional mechanical and ultrasonic processing. Research Methods. To conduct the experiments, a set of welding equipment was used — a single-phase inverter device KEMPPI Kempomat 1701, designed for welding with wire in shielding gases. A mixture of argon and carbon dioxide (80 % argon and 20 % CO2) was used as a shielding gas. SV-08G2S (0.8 C-2 Mg-Si) wire was used as the surfacing material. A plate made of steel St3 with overall dimensions 150×100×5 mm was used as a base for surfacing. The surface of the plate before surfacing was thoroughly cleaned from the layer of oxides, oil, rust and other contaminants. For this purpose mechanical cleaning of the surface was used with BOSCH abrasive wheel with a diameter of 125 mm diameter and a grit size of 120. Before surfacing the surface of the product was degreased with white spirit. The gas flow rate was set at 8 dm3/min. To select the optimal wire feed rate and volt-ampere characteristic, surfacing was performed at each adjustment step of wire feed rate, and voltage. Mechanical statistical tensile tests, chemical composition analysis and metallographic studies were also performed. Results and Discussion. Gas porosity is a typical defect that occurs during the WAAM process and should be eliminated because it adversely affects the mechanical properties. Initially, gas porosity leads to a reduction in the mechanical strength of the part due to damage from microcrack formation. In addition, it often causes the surfaced layer to have worse fatigue properties due to the spatial distribution of different shape and size structures. In our experiments we found that a wire feed speed range of 5–6 m/min is optimal. Increasing the flow rate of shielding gas in the range of 8–14 l/min allows reducing porosity in the surfaced metal to almost zero. The mechanical properties of the surfaced beads show that the average value of yield strength after machining is higher than that of unprocessed specimens. The data obtained from these experiments are in good agreement with those reported in the literature. The presented results can be used in real WAAM technological processes.

Near-Field Direct Writing Based on Piezoelectric Micromotion for the Programmable Manufacturing of Serpentine Structures

Serpentine microstructures offer excellent physical properties, making them highly promising in applications in stretchable electronics and tissue engineering. However, existing fabrication methods, such as electrospinning and lithography, face significant challenges in producing microscale serpentine structures that are cost-effective, efficient, and controllable. These methods often struggle with achieving precise control over fiber morphology and scalability. In this study, we developed a near-field direct writing (NFDW) technique incorporating piezoelectric micromotion to enable the precise fabrication of serpentine micro-/nanofibers by incorporating micromotion control with macroscopic movement. Modifying the fiber structure allowed for adjustments to the mechanical properties, including tunable extensibility and distinct characteristics. Through the control of the frequency and amplitude of the piezoelectric signal, the printing errors were reduced to below 9.48% in the cycle length direction and 6.33% in the peak height direction. A predictive model for the geometrical extensibility of serpentine structures was derived from Legendre’s incomplete elliptic integral of the second kind and incorporated an error correction factor, which significantly reduced the calculation errors in predicting geometric elongation, by 95.85%. The relationship between microstructure bending and biomimetic non-linear mechanical behavior was explored through tensile testing. By controlling the input electrical signals, highly ordered serpentine microstructures were successfully fabricated, demonstrating potential for use in biomimetic mechanical scaffolds.

Simultaneous determination of refined values of mobility, channel and contact resistance in organic field-effect transistors utilizing the four- and three-probe methods

Abstract Accurate determination of charge carrier mobility is a critical aspect in an organic field-effect transistor (OFET) as it is tightly correlated to the development of new materials, better device designs and improved fabrication methods. The presence of high contact resistance at the metal–organic semiconductor interface introduces an intrinsic error in the extraction of charge carrier mobility. In this report, electrical circuit analysis for the determination of the refined channel mobility, total contact resistance and channel resistance values is showcased for a poly(3-hexylthiophene) OFET with bottom-gate bottom-contact architecture. The process of determination is based on the combination of the conventional four-probe and three-probe measurement techniques. These two techniques are used in conjunction to assess refined mobility values in the channel region. This is followed by the determination of total contact resistance and channel resistances. The results show that, at a fixed drain current, mobility increases with the gate voltage while both the contact and channel resistances decrease.

The Effects of Manufacturing Errors on the Performance of Acoustic Metamaterial Lenses Operating in the MHz Regime

This article explores the use of acoustical metamaterials to design lenses in the megahertz frequency range of relevance to applications in nondestructive testing and medical imaging. In particular, the effect of manufacturing errors on their focusing performance is quantified. A rapid method for including manufacturing errors is described and this is used to perform Monte Carlo simulations of wave pressure fields from lenses with manufacturing errors. In this process, the required time delay distribution for a target focal length is calculated and the acoustical lenses with a chosen unit cell type are designed. Manufacturing errors of the unit cells are then added, considering their statistical properties and a large number of realizations. As an example, an acoustical lens with a focal length of 76 mm at a frequency of 1 MHz is designed using three different unit cell types: steel cross unit cell, resin circular void unit cell, and silicone–resin layered unit cell. Finally, the resulting acoustic pressure fields are computed using a Huygens’ principle model to assess the effects of manufacturing errors on lens performance, i.e., the focal length and the size of the focal spot. It is shown that the performance of lenses consisting of silicone–resin layered units is less affected by the manufacturing errors than for lenses constructed with the other unit cells. This study paves the way for selecting a suitable combination of metamaterial unit cell and manufacturing method to enable acceptable lens imaging performance.

Microstructure, Recovery Stress and Mechanical Property of Direct Energy Deposition Welded Fe-Mn-Si Based Shape Memory Alloy

Direct Energy Deposition (DED) is one of the main methods of additive manufacturing in which a feedstock material in the form of powder or wire is delivered to a substrate while an energy source, such as laser beam or electron beam, is simultaneously applied to melt the feedstock. In addition to fabricating complex three-dimensional shapes using computer aided design, the DED laser welding process can be employed to fill complex shaped gaps between two objects. In this study, 3 mm thick Fe-based shape memory alloy plates with a 45° groove were welded by DED using high manganese steel powder filler. The process parameters including scan speed, hatch spacing, and layer thickness were fixed at values of 840 mm/min, 0.3 mm, 0.15 mm, respectively and laser power was varied during the welding process from 150 W to 300 W. Microstructures of the welds showed different shapes and quantities of defects such as cracks, pores and a lack of fusion depending on the laser power used. Laser power of 150 W showed crack-free weldment with the highest mechanical properties. The tensile strength and recovery stress of the welded sample were higher than the base metal, demonstrating the potential high performance of welding Fe-Mn-Si shape memory alloy components using the L-DED.

Effect of stretching ratio on the structure and enactment of porous PVDF-HFP hollow fiber membranes for CO2 absorption

Carbon dioxide (CO2) is responsible for increment of the Earth surface temperature and the subsequent environmental issues. In this regard, membrane contactor is one of the emerging technologies that can be applied for controlling CO2 emission. More specifically, the intrinsic structure of membrane plays an important role to govern the performance of CO2 absorption. In this study, considering stretching ratio (SR) as a key factor to affect membrane structural properties, highly porous poly(vinylidene fluoride-co-hexafluoropropylene) (PVDF-HFP) hollow fiber membranes were fabricated by a non-solvent induced phase separation method. The results showed that the membrane dimension and thickness were significantly reduced by optimizing the SR. The optimum membrane structure was found at SR of 1.5 where the mean pore size, CO2 permeance, collapsing pressure and liquid entry pressure of 0.032 μm, 3440 GPU, 550 kPa and 500 kPa were achieved, respectively. The prepared membranes showed open structure with overall porosity of more than 80%. The upgraded membrane at SR of 1.5 presented the maximum CO2 absorption flux of 9.8 × 10− 4 mol/m2 s and the minimum mass transfer resistance of 49,544 (m/s)−1. Furthermore, a stable CO2 absorption performance was achieved during 80 h continuous operation with a flux decline of only about 9%. The findings of this work demonstrated that by applying a cost-effective fabrication method, we can potentially enhance the PVDF-HFP membrane properties for CO2 adsorption without requiring an additional post-modification step.

Optimizing operations of flexible assembly systems: demonstration of a digital twin concept with optimized planning and control, sensors and visualization

AbstractThis paper presents the development of an optimized planning and control method for flexible manufacturing and assembly systems. While the significant potential of flexible manufacturing concepts to help producers adapt to market developments is recognized, the complexity of the flexible systems and the need to optimally plan and control them is a major obstacle in their practical implementation. Thus, this paper aims to develop a comprehensive digital planning method, based on a digital twin and to demonstrate the feasibility of the approach for practical application scenarios. The approach consists of four modules: (1) a simulation-based optimization module that applies reinforcement learning and genetic algorithms to optimize the module configuration and job routing in cellular reconfigurable manufacturing systems; (2) a synchronization module that links the physical and virtual systems via sensors and event handling; (3) a sensor module that enables a continuous status update for the digital twin; and (4) a visualization module that communicates the optimized plans and control measures to the shop floor staff. The demonstrator implementation and evaluation are implemented in a learning factory. The results include solutions for the method components and demonstrate their successful interaction in a digital twin, while also pointing towards the current technology readiness and future work required to transfer this demonstrator implementation to a full-scale industrial implementation.