Integrated Physical and Digital Twins in Materials Processing

Materials-intensive industries face continual challenges in ensuring sustainability in manufacturing, particularly the need to reduce carbon footprints while enhancing product quality, developing new products, and reducing production costs. To overcome these challenges, manufacturers must gain better understanding and control of both the processing equipment and the materials as they undergo various manufacturing stages. Modern materials are often multi-component, multiphase systems with complex responses to processing conditions making them difficult to monitor, predict, and control. This necessitates a holistic strategy that integrates experimental and real-time sensor data with physics-based and data-driven modelling techniques for real-time optimisation of materials and manufacturing processes.

This is an in-person course which will take place over 3 consecutive days, from 13th to 15th October, 2025.

WHY ATTEND?

1. Gain insights into cutting-edge digital and physical twin technologies.

2. Enhance your ability to optimise materials and manufacturing processes.

3. Acquire hands-on experience with modern experimental and modelling methods.

4. Network with industry experts and peers in materials science and manufacturing.

5. Improve operational efficiency and sustainability through advanced digital tools.

WHO SHOULD ATTEND?

• Engineers and technical specialists in manufacturing and materials processing.
• Materials scientists, metallurgists, and R&D professionals.
• Industry professionals involved in quality control and process optimisation.

COURSE OBJECTIVES

• Understand the concepts and applications of digital and physical twins in materials processing.
• Gain practical knowledge of data acquisition, processing, and integration techniques.
• Develop skills in physics-based and data-driven modelling for materials optimisation.
• Learn to implement digital twin technologies in manufacturing environments.
• Enhance their capability to analyse and optimise complex materials and manufacturing systems.
• Collaborate with industry and academic leaders to explore innovative solutions.

COURSE CONTENT

Module 1: Introduction

• Challenges in materials processing and top-down approaches.
• Physical and digital twins, their evolution, and their role in materials processing.

Module 2: Data Acquisition

• Physical simulation methods, e.g., DSC and thermal-mechanical simulation (Gleeble).
• Characterisation methods, microstructural, e.g., EBSD, TEM and APT.
• Digitalisation of experimental data.
• Realtime data acquisition, e.g., advanced temperature sensing technologies.

Module 3: Physics-based Modelling

• Modelling to guide experiments and to generate extrapolated data for training.
• Mean-field and thermodynamic modelling.
• Full-field numerical simulation techniques, e.g., FEA and the phase-field method.

Module 4: Data-driven Modelling

• Machine learning methods, incl. physics informed ML to improve accuracy.
• Uncertainty analysis, incl. specific techniques and their scope of application.

SUBJECT MATTER EXPERTS

Prof. Hamid Assadi – Course Lead

Dr Chamini Mendis – Course Expert

Dr Ebad Bagherpour – Course Expert

Prof. Isaac Chang – Course Expert

Dr. James Famelton – Course Expert

Dr Mian Zhou – Course Expert

Prof. Phillip Stanley Marbell – Course Expert

Dr. Chandra Bhanu Basak – Course Expert

Dr. Amin Amini - Course Expert

Certification

All participants will be issued with a certificate of course completion.

Important Dates:

• 19th June, 2025 – Deadline for early bird registration (10% discount)
• 19th August, 2025 – Full registration
• 13th - 15th October, 2025 – Course dates

How to register?

Register your interest by claiming a free ticket on this Eventbrite page. After registration, you'll receive detailed course fee and payment information via email.

Important: To guarantee hotel accommodation, we strongly recommend registering by the early bird deadline. If you register after this date, you may need to arrange your own accommodation. In such cases, the necessary reductions will be made, and the course fee will be recalculated accordingly.

If you require a visa invitation letter, please let us know, and we’ll be happy to assist.

Limited spaces are available—apply now to secure your spot!

Get in touch today! - bcast-training@brunel.ac.uk

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