Two Alabama universities have received a grant to help manufacturers incorporate artificial intelligence (AI) and digital twins into production processes.
The University of Alabama in Huntsville (UAH) and The University of Alabama (UA) are partners in a new economic development initiative – Smart Manufacturing using AI-based Revolutionary Technologies (SMART) – funded by a grant from the National Science Foundation Industry University Cooperative Research Center.
The SMART Center will partner with companies to gather data from sensors and cameras during real-world manufacturing operations. This information will be used to design and integrate AI-driven solutions that boost productivity, enhance product quality, improve factory sustainability, and strengthen workforce safety.
AI and digital twins in manufacturing
Manufacturers are increasingly leveraging the capabilities of AI and machine learning to achieve new levels of efficiency and production control, according to Marc Wren, OT cyber security manager Axians UK.
“Autonomous planning is a use of AI that is being rapidly adopted across the manufacturing industry. AI algorithms analyze real-time data on inventory levels, production capacity, and customer demand as well allowing manufacturers to maintain a consistent supply performance by analyzing historical data on material usage, lead times, and potential disruptions.
Meanwhile, over 40 percent of manufacturing firms are piloting digital twin technology with full rollouts continuing to emerge, according to the Manufacturing IT/OT Trend Report 2025.
Of the organizations that have used digital twin technology, 65 percent have seen downtime and operational costs reduced. More than half (55 percent) report improved predictive maintenance, while 40 percent have achieved better collaboration. Enhanced planning and efficiency (35 percent) and real-time simulation (25 percent) follow. Just 15 percent saw no measurable impact so far.
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Helping manufacturers boost production processes with AI and digital twins
The SMART Center will share its broadly applicable solutions across the manufacturing sector to help elevate the global competitiveness of US industry through technological innovation and targeted workforce training.
By fostering collaboration among universities, industry partners, and government agencies, the SMART Center will advance national efforts to build economic resilience and accelerate innovation in advanced manufacturing.
“What we’re facing with advanced manufacturing is how to incorporate all the new tools coming down the pipeline,” said Dr Judith Schneider, professor, Department of Mechanical and Aerospace Engineering, adjunct, Department of Chemical and Materials Engineering, and director, UAH Materials Science Program. “It can be hard for companies to implement the new tools because they’re not trained to use them. While these companies lack the training, universities are currently training their future employees to fill that gap.”