Work

Agentic AI-Enabled Digital Twins for Intelligent Non-Destructive Testing of 3D-Printed Rehabilitation Equipment—A Narrative Review

Year: 2026

Type: review

Abstract: Digital twins (DTs) based on agent-based artificial intelligence (Agentic AI) provide a transformative framework for streamlining nondestructive testing (NDT) of 3D-printed rehabilitation equipment. This study applies a conceptual research methodology based on the integration and analysis of recent advances in Agentic AI, digital twin architectures, additive manufacturing, NDT technologies, and intelligent rehabilitation systems to establish a framework for autonomous quality monitoring and lifecycle management of 3D-printed medical devices. By creating intelligent virtual replicas of physical devices, these systems enable continuous monitoring of structural integrity, functional performance, and degradation mechanisms throughout the product lifecycle. Unlike conventional AI-based DTs, Agentic AI-driven DTs can autonomously perceive, reason, plan, and execute corrective actions based on real-time sensor data, NDT results, manufacturing information, and historical knowledge. The main conclusion of this work is that Agentic AI-enhanced DTs have the potential to transform NDT from a passive inspection approach into an intelligent, predictive, and autonomous decision-support system for rehabilitation equipment. Advanced machine learning and autonomous decision-making algorithms enable the identification of early signs of material degradation, manufacturing defects, fatigue accumulation, and performance anomalies, supporting predictive maintenance and proactive quality assurance. Integrating Agentic AI DTs with additive manufacturing processes enables real-time optimization of printing parameters, adaptive process control, and continuous refinement of inspection strategies without production interruption or destructive sampling, thereby supporting Industry 4.0 and smart manufacturing principles. The main innovation of this research lies in proposing an autonomous closed-loop framework that combines Agentic AI, DTs, additive manufacturing, and NDT into a unified system capable of continuous learning, reasoning, and operational optimization. Compared with existing studies that mainly focus on AI-assisted defect detection or static digital twin models, this approach introduces autonomous agents capable of coordinating sensing, simulation, diagnosis, prediction, and corrective actions across the entire lifecycle of 3D-printed rehabilitation devices. The proposed concept extends current digital twin applications by incorporating virtual stress testing, autonomous simulation, patient-specific customization, and adaptive device management, reducing dependence on physical prototypes, minimizing material waste, and accelerating design validation. By combining autonomous reasoning with predictive analytics, Agentic AI-based DTs represent a next-generation solution for intelligent, adaptive, and sustainable nondestructive testing, advancing both additive manufacturing technologies and personalized rehabilitation engineering.

Source: Applied Sciences

DOI: 10.3390/app16189001

Authors: Emilia Mikołajewska, Urszula Rogalla-Ładniak, Jolanta Masiak, Ewelina Panas, Dariusz Mikołajewski

Institutions: Nicolaus Copernicus University, Medical University of Lublin, Maria Curie-Skłodowska University, Kazimierz Wielki University in Bydgoszcz

Language: English

Topic: Digital Transformation in Industry

Subfield: Industrial and Manufacturing Engineering

Field: Engineering

Domain: Physical Sciences

SDGs: Industry, innovation and infrastructure, Good health and well-being

Open Access status: gold

Estimated APC paid: $2,896