Digitally twinned additive manufacturing: Detecting flaws in laser powder bed fusion by combining thermal simulations with in-situ meltpool sensor data

•A novel digital twin method for real-time flaw detection in laser powder bed fusion.•Approach combines in-situ meltpool temperature measurements with computational predictions.•Three types of flaws considered from processing, machine, and cyber intrusions.•Digital twin approach detects all the three types of flaws.•Characterization of flaws and microstructure analysis confirms the proposed approach.