The paper highlights a clear shift from conventional simulation models towards hybrid digital twins that combine physics-based models with data-driven algorithms. In MAXIMA and the other motor-focused projects, these digital twins are used to evaluate electromagnetic, thermal and mechanical behaviour throughout the design process, enabling virtual validation of motor concepts before physical prototyping.

A key technical theme is the use of FMU/FMI standards to integrate models developed by different partners into a common digital twin environment while preserving intellectual property. This approach allows multidisciplinary simulations spanning electric machines, power electronics, thermal management and control systems.

The paper also shows how digital twins are moving closer to real-time operation. Rather than being limited to offline design activities, they are increasingly deployed for predictive control, condition monitoring and lifetime assessment. In the HiPE project, for example, digital twin-based prognostics and health management strategies demonstrated a 17-fold extension of remaining useful life (RUL) for power electronic components through predictive maintenance and intelligent operating strategies.

Another important finding is the emergence of digital thread architectures, linking design, manufacturing, operation and end-of-life phases. This enables continuous tracking of component performance and degradation, supporting circularity objectives such as lifetime extension, remanufacturing and more efficient use of critical raw materials.

Overall, the paper identifies hybrid modelling, FMI-based integration and embedded deployment as converging best practices that are enabling digital twins to become operational tools for the next generation of high-efficiency electric propulsion systems.

Read the full paper here