Rutgers Develops Digital Twin Framework to Combat Cyberattacks in Manufacturing

Manufacturing remains the most targeted industry for cyberattacks, accounting for 27.7% of incidents in 2026. The median cost of a ransomware attack in manufacturing reached $600,000, with total losses potentially in the millions. A Rutgers University team, led by Rajiv Malhotra, has proposed a dual digital twin approach to enhance cybersecurity in additive manufacturing. This method aims to maintain production continuity during cyberattacks by using geometric and process digital twins to detect and correct defects in real-time. Traditional methods often require shutting down production, which can take weeks to resolve. The Rutgers framework is designed to address the challenges of scaling resilience amidst complex supply chains and material constraints. The team is collaborating with industry partners to commercialize this technology for manufacturing facilities. Future research will expand to include attacks on sensor signals and hybrid manufacturing systems.

Key Points: • Manufacturing is the most targeted sector for cyberattacks, with 27.7% of incidents in 2026. • Rutgers University proposes a dual digital twin approach to enhance cybersecurity in additive manufacturing. • The new framework allows for uninterrupted production during cyberattacks by correcting defects in real-time.