Digital-Twin-Enabled Human–Machine Collaboration Systems in Sustainable Smart Manufacturing: System Architecture, Development Methods, Applications, and Future Trends

Abstract

Digital-twin-enabled human–machine collaboration (HMC) has increasingly been proposed as a system-level approach for connecting human operators, robots, sensors, artificial intelligence modules, and manufacturing resources. However, the literature varies substantially in what is called a digital twin, how physical and virtual models are coupled, whether models are updated from physical data, and how far systems have progressed beyond simulation or controlled laboratory demonstrations. This structured integrative review examines the conditions under which a digital twin can function as an integration layer for HMC in sustainable smart manufacturing, rather than assuming that such integration is already established industrial practice. The literature corpus was assembled through searches of the Web of Science Core Collection, Scopus, and IEEE Xplore, complemented by Google Scholar-based citation tracking and backward and forward citation tracing. The core search focused on studies published from 1 January 2020 to 5 August 2026, while earlier seminal studies were retained to support definitions and historical context. Studies were screened using explicit criteria for manufacturing relevance, physical–virtual coupling, state synchronization or model updating, feedback capability, and validation setting, and were critically coded by model type, integration mechanism, deployment maturity, and sustainability evidence. The review compares multimodal perception and human-state modeling, intention understanding and augmented interaction, task allocation and shared planning, digital-twin architectures, adaptive control and safety verification, and human–AI decision-making. The evidence indicates that digital twins are promising as coordination and verification layers, but many reported systems remain conceptual, simulation-based, or limited to controlled physical prototypes. Key barriers include model fidelity, online model updating, real-time synchronization, cross-platform interoperability, safety assurance, human-data governance, and the limited availability of directly measured sustainability outcomes. Future work should prioritize validated hybrid models, traceable model-update mechanisms, staged virtual-to-physical deployment, interoperable data contracts, and longitudinal evaluation of technical, human, economic, and environmental performance.