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Digital Twin
Why manufacturers should rely on Digital Twins

A Digital Twin is the virtual representation of a physical product.
For manufacturers, it means the efficient provision of intelligent product data throughout the entire life cycle, while designers and engineers use it to plan and simulate components realistically and integrate them into projects.

What is a Digital Twin?

A Digital Twin is the digital representation of a real product, machine, or entire plant. It encompasses much more than just geometry: supplemented by properties such as material, weight, kinematics, or behavior, the physical object can be experienced virtually. This allows products to be simulated, analyzed, and optimized in the digital world even before they physically exist.

Its added value is particularly evident in its application: engineers and planners can test complex scenarios safely, while manufacturers can place their products in projects at an early stage and meet their customers' requirements in a targeted manner.

How does a Digital Twin work?

A Digital Twin is made up of various components.
In addition to pure geometric data, intelligent additional information is required to turn a 3D model into a fully-fledged digital image.
This is also referred to as 4D data: 3D geometry combined with behavior and time.
A distinction is also made between different levels of twins – from individual components to complete systems.

 

 

Intelligent engineering data as a basis

This data expands the digital model and makes it usable for development, simulation, and operation.

Efficient product development

Engineers use data to run simulations and iterate on design projects. This accelerates development time and time to market.

Integration of IoT and sensor data

This opens up opportunities to monitor and optimize throughout the entire product lifecycle.

Maintenance and repair

Intelligent engineering data plays an important role in plant and system maintenance and repair.

Types of Digital Twins

Depending on the level of detail, there are different types of Twins that perform different tasks.

Component twins

The basic building blocks of the Digital Twin represent individual functioning components.

Asset twins

Asset twins are created when multiple components interact and provide important performance data for analysis and optimization.

System or unit twins

System or unit twins map entire systems, highlight interactions, and reveal potential for improvement.

The standard for Digital Twins

The Asset Administration Shell is the digital image of a physical product – structured, standardized, and ready for use in Industry 4.0 applications. CADENAS enables companies to adopt this technology early, ensuring information is delivered efficiently, in a standardized format, and across manufacturers.

Digital Twins – Why they are the future of products and processes

Digital Twins are much more than 3D models. They digitally map products throughout their entire life cycle and create a common data basis for development, manufacturing, operation, and maintenance. For manufacturers, this means new opportunities in product development – for designers and engineers, it means more efficient planning and realistic simulation.

  • Earlier project integration
    Products are already taken into account in the digital planning phase.

  • Cost and time savings
    Virtual tests reduce errors and accelerate market launch.

  • Standard in Industry 4.0
    OEMs and planners expect digital product data.

  • Better decisions
    Simulations provide valuable insights for operation and optimization.

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    Virtual commissioning (VIBN) as a key factor

    Many industries and companies are already relying on virtual commissioning. VIBN is particularly widespread in the automotive, aerospace, manufacturing, and robotics industries. Here, teams use Digital Twins to digitally test systems and processes before they are actually built—problems become visible before they become expensive.

  • Simulation before production start
    Processes, clearances, and integrations are checked virtually, long before the first physical setup.
  • Optimize performance
    Parameters such as speeds, loads, or control logic can be varied and specifically improved.
  • Reduce risks
    Critical scenarios can be safely simulated digitally, reducing ramp-up times and minimizing malfunctions.

    • The embedded video and interactive 3D model illustrate the VIBN.



    Digital Twins – your competitive advantage

    Whether in the automotive, construction, or mechanical engineering industries, we support manufacturers in preparing their products as Digital Twins and making them available in all relevant formats. Concrete use cases and references from leading companies show how this works in practice.

    Provide your products as Digital Twins

    Whether in the automotive, construction, or mechanical engineering industries, Digital Twins have long been indispensable. Make your products available digitally and secure visibility in the projects of tomorrow. We support you in creating Digital Twins.

     

  • Member of the IDTA – we are actively shaping the standards for Digital Twins.

  • Technology of the future – Digital Twins are key to Industry 4.0 and BIM.

  • Market requirement – without digital product data, manufacturers are increasingly being excluded from projects.

  • Competitive advantage – early project integration increases sales opportunities and customer access.

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    Frequently asked questions about Digital Twins

    What is a Digital Twin?
    A Digital Twin is the digital representation of a physical product, machine, or plant. In addition to geometry, it also contains additional information such as material, behavior, and kinematics, enabling simulation and optimization.
    What is the difference between a CAD model and a Digital Twin?
    A CAD model primarily depicts the geometry. A Digital Twin goes much further: it supplements this geometry with metadata, behavior, and lifecycle information so that it can be used for simulation, operation, and maintenance.
    Why are Digital Twins important for manufacturers?
    Manufacturers can use Digital Twins to place their products in projects at an early stage, meet customer requirements, and increase their visibility among designers, planners, and OEMs. They also accelerate development processes and reduce costs.
    In which industries are Digital Twins used?
    Digital Twins are established in many areas, such as mechanical engineering, the automotive industry, aerospace, construction, and robotics. They are used wherever products are developed, simulated, or integrated into complex systems.