Digital Twins as Enablers of Sustainable, High-Performance EV Propulsion and Electronics: Insights from EU 2ZERO Projects

This work synthesizes how Digital Twins (DTs) are enabling next-generation electric drive and power electronics systems within European 2ZERO projects, funded through Horizon Europe calls that emphasize efficiency, cost reduction, circularity, and reduced reliance on critical raw materials. Several initiatives supported under HORIZON-CL5-2022-D5-01-09 (including HEFT, VOLTCAR, CliMAFlux, and MAXIMA) focus on the development of high efficiency, low-cost electric motors designed for circularity. DTs within these projects enable lifecycleaware design, digital validation, predictive control, and facilitate circular strategies via multidisciplinary model integration and real-time monitoring. In parallel, HiPE, funded under HORIZON-CL5-2021-D5-01-02, focuses on wide-bandgap (WBG) power electronics and exploits DTs for predictive control, reliability, and system optimization. This paper presents detailed technical approaches from a crossproject workshop held in February 2026, revealing convergent best practices including hybrid physics-AI modeling, FMU/FMI-based integration, and embedded deployment strategies.

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