A “digital twin” is a dynamic, digital replica of a technical object (e.g., a physical system, device, machine or production process) or a living organism. Using this type of solution has become an integral part of Industry 4.0, offering businesses tangible benefits, in addition to being particularly effective within the context of sustainable production and maintenance. The purpose of this paper is to present the results of research on the development of digital twins of technical objects, which involved data acquisition and their conversion into knowledge, the use of physical models to simulate tasks and processes, and the use of simulation models to improve the physical tasks and processes. In addition, monitoring processes and process parameters allow for the continued improvement of existing processes as regards intelligent eco-designing and planning and monitoring production processes while taking into account sustainable production and maintenance.

Maintenance of production equipment has a key role in ensuring business continuity and productivity. Determining the implementation time and the appropriate selection of the scope of maintenance activities are necessary not only for the operation of industrial equipment but also for effective planning of the demand for own maintenance resources (spare parts, people, finances). A number of studies have been conducted in the last decade and many attempts have been made to use artificial intelligence (AI) techniques to model and manage maintenance. The aim of the article is to discuss the possibility of using AI methods and techniques to anticipate possible failures and respond to them in advance by carrying out maintenance activities in an appropriate and timely manner. The indirect aim of these studies is to achieve more effective management of maintenance activities. The main method applied is computational analysis and simulation based on the real industrial data set. The main results show that the effective use of preventive maintenance requires large amounts of reliable annotated sensor data and well-trained machine-learning algorithms. Scientific and technical development of the above-mentioned group of solutions should be implemented in such a way that they can be used by companies of equal size and with different production profiles. Even relatively simple solutions as presented in the article can be helpful here, offering high efficiency at low implementation costs.

While the intensity, complexity, and specificity of robotic exercise may be supported by patient-tailored three-dimensional (3D)-printed solutions, their performance can still be compromised by non-optimal combinations of technological parameters and material features. The main focus of this paper was the computational optimization of the 3D-printing process in terms of features and material selection in order to achieve the maximum tensile force of a hand exoskeleton component, based on artificial neural network (ANN) optimization supported by genetic algorithms (GA). The creation and 3D-printing of the selected component was achieved using Cura 0.1.5 software and 3D-printed using fused filament fabrication (FFF) technology. To optimize the material and process parameters we compared ten selected parameters of the two distinct printing materials (polylactic acid (PLA), PLA+) using ANN supported by GA built and trained in the MATLAB environment. To determine the maximum tensile force of the exoskeleton, samples were tested using an INSTRON 5966 universal testing machine. While the balance between the technical requirements and user safety constraints requires further analysis, the PLA-based 3D-printing parameters have been optimized. Additive manufacturing may support the successful printing of usable/functional exoskeleton components. The network indicated which material should be selected: Namely PLA+. AI-based optimization may play a key role in increasing the performance and safety of the final product and supporting constraint satisfaction in patient-tailored solutions.

The last decade has seen the development of complex IT systems to support city management, i.e., the creation of so-called intelligent cities. These systems include modules dedicated to particular branches of municipal economy, such as urban transport, heating systems, energy systems, telecommunications, and finally water and sewage management. In turn, with regard to the latter branch, IT systems supporting the management of water supply and sewage networks and sewage treatment plants are being developed. This paper deals with the system concerning the urban water supply network, and in particular, with the subsystem for detecting and locating leakages on the water supply network, including so-called hidden leakages. These leaks cause the greatest water losses in networks, especially in old ones, with a very diverse age and material structure. In the proposed concept of the subsystem consisting of a GIS (Geographical Information System), SCADA (Supervisory Control and Data Acquisition) system and hydraulic model of the water supply network, an algorithm of leak detection and location based on the neural networks’ MLP (multi-layer perceptron) and Kohonen was developed. The algorithm has been tested on the hydraulic models of several municipal water supply networks.

Overview: Photovoltaic (PV) systems are widely used in residential applications in Poland and Europe due to increasing environmental concerns and fossil fuel energy prices. Energy management strategies for residential systems (1.2 million prosumer PV installations in Poland) play an important role in reducing energy bills and maximizing profits. Problem: This article aims to check how predictable the operation of a household PV system is in the short term—such predictions are usually made 24 h in advance. Methods: We made a comparative study of different energy management strategies based on a real household profile (selected energy storage installation) based on both traditional methods and various artificial intelligence (AI) tools, which is a new approach, so far rarely used and underutilized, and may inspire further research, including those based on the paradigm of Industry 4.0 and, increasingly, Industry 5.0. Results: This paper discusses the results for different operational scenarios, considering two prosumer billing systems in Poland (net metering and net billing). Conclusions: Insights into future research directions and their limitations due to legal status, etc., are presented. The novelty and contribution lies in the demonstration that, in the case of domestic PV grids, even simple AI solutions can prove effective in inference and forecasting to support energy flow management and make it more predictable and efficient.

IoT applications for building energy management, enhanced by artificial intelligence (AI), have the potential to transform how energy is consumed, monitored, and optimized, especially in distributed energy systems. By using IoT sensors and smart meters, buildings can collect real-time data on energy usage patterns, occupancy, temperature, and lighting conditions.AI algorithms then analyze this data to identify inefficiencies, predict energy demand, and suggest or automate adjustments to optimize energy use. Integrating renewable energy sources, such as solar panels and wind turbines, into distributed systems uses IoT-based monitoring to ensure maximum efficiency in energy generation and use. These systems also enable dynamic energy pricing and load balancing, allowing buildings to participate in smart grids by storing or selling excess energy.AI-based predictive maintenance ensures that renewable energy systems, such as inverters and batteries, operate efficiently, minimizing downtime. The case studies show how IoT and AI are driving sustainable development by reducing energy consumption and carbon footprints in residential, commercial, and industrial buildings. Blockchain and IoT can further secure transactions and data in distributed systems, increasing trust, sustainability, and scalability. The combination of IoT, AI, and renewable energy sources is in line with global energy trends, promoting decentralized and greener energy systems. The case study highlights that adopting IoT and AI for energy management offers not only environmental benefits but also economic benefits, such as cost savings and energy independence. The best achieved accuracy was 0.8179 (RMSE 0.01). The overall effectiveness rating was 9/10; thus, AI-based IoT solutions are a feasible, cost-effective, and sustainable approach to office energy management.