Research progress on digital-twin-driven full life-cycle design and manufacturing of rehabilitation assistive devices.

Digital Twin (DT) technology has emerged as a promising paradigm for the design, optimization, and lifecycle management of rehabilitation assistive devices. However, existing studies are often limited to specific technologies or applications, lacking a systematic perspective on different device categories and their lifecycle requirements. This review summarizes recent advances in DT-driven rehabilitation assistive devices. A DT-oriented taxonomy is proposed, classifying rehabilitation assistive devices into structure-oriented, human-device coupled, and intelligent interactive devices according to their functional requirements. Based on this taxonomy, a lifecycle-oriented DT framework is established, encompassing multimodal data acquisition, digital modeling, simulation and optimization, manufacturing integration, and closed-loop feedback updating. Key enabling technologies, including biomechanical modeling, finite element analysis, artificial intelligence, multi-source data fusion, and additive manufacturing, are systematically reviewed. Representative applications are further analyzed to illustrate the role of DT in personalized design, performance prediction, adaptive control, and intelligent manufacturing. The review indicates that DT technology can significantly improve personalization, performance optimization, and lifecycle management of rehabilitation assistive devices. Despite challenges in data interoperability, real-time computation, and clinical validation, DT is expected to play an increasingly important role in advancing intelligent, precise, and personalized rehabilitation. This review provides a structured reference for future research and practical implementation of DT technologies in rehabilitation engineering.