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The biometric community is faced with the difficult problem of protection of the original biometric template. One way of doing this is using a cancelable biometric method, which transforms original biometric template in a noninvertible way and uses the transformed template to verify a person's identity. In this paper, we propose two novel representation methods for fingerprint minutiae. Proposed methods based on this representation are simple to generate cancelable templates without requiring pre-alignment of the fingerprints. The main idea is to generate a minimal spanning tree (MST) for fingerprint minutiae in a three-dimensional (3D) feature space. The chain code representation for a generated MST in a two-dimensional (2D) feature space is proposed. A bit string is then generated by mapping the chain code into 2D array. The fingerprint minutiae based upon the Cartesian system is dealt with in Method-1, while the boundary representation of the minutiae is dealt with in Method-2. The proposed methods are evaluated using FVC2004 and FVC2002 databases and the performance is better compared to existing methods [C. Lee and J. Kim, J. Netw. Comput. Appl.33(3) (2010) 236–246; S. Wang and J. Hu, Pattern Recogn.45 (2012) 4129–4137; S. Wang and J. Hu, Pattern Recogn.47(3) (2014) 1321–1329; Z. Jin, A. B. J. Teoh, T. S. Ong and C. Tee, Expert Syst. Appl.39 (2012) 6157–6167; P. Das, K. Karthik and B. C. Garai, Pattern Recogn.45(9) (2012) 3373–3388; A. B. J. Teoh, D. C. L. Ngo and A. Goh, Pattern Recogn.37(11) (2004) 2245–2255.]

In the realm of advanced manufacturing, the integration of digital technologies has revolutionized industrial processes; this paper explores the fusion of nature-inspired design principles with advanced robotics in the context of a Cartesian pneumatically controlled robotic system. Leveraging the elegance of biomimicry, the system integrates a claw-inspired gripper for precision pick-and-place operations. The study employs digital twin technology to enhance the understanding and optimization of the robotic system. By embracing nature-driven design, the Cartesian robotic arm is engineered for enhanced efficiency and adaptability. The biomimetic approach not only improves performance but also aligns with sustainability goals. The abstract encapsulates the essence of harmonizing Cartesian systems, pneumatic control, claw-inspired gripper, digital twins, pick-and-place operations, and nature-driven design to advance the forefront of robotics and automation. Furthermore, this paper addresses the aspect of human–robot collaboration by considering safety protocols and collision avoidance mechanisms when the robot operates in proximity to human workers. The digital twin’s potential extends beyond replication and optimization, paving the way for safer and more efficient manufacturing processes. The report details the entire development process, from the initial understanding of the physical system to creating the digital twin. This work signifies a valuable contribution to manufacturing, robotics, and digital simulation, offering a versatile tool for optimizing industrial processes and enhancing the efficiency of Cartesian robot-assisted plastic injection moulding operations.