What Is Digital Twin Technology, And What Are Some Real-World Examples?

Digital Twin

A digital twin is a computerized version of a real object, process, or service that you can see and touch. One example of a “digital twin” is a digital version of an object in the real world, such as a jet engine or wind farm. It can also be a bigger thing, like buildings or even whole cities!

The digital twin technology can also be used to make copies of processes so that data can be gathered to predict how well they will work.

It is like a computer program that uses real-world data to make computer simulations that can predict how a product or process will work. A digital twin is like this: These programmers can work with the internet of things (Industry 4.0), artificial intelligence, and software analytics to improve the output of your work.

With the development of machine learning and factors like big data, these virtual models have become an important part of modern engineering. They help engineers come up with new ideas and improve their performance.

To put it simply, making one can help strategic technology trends, avoid costly failures in physical objects, and test processes and services with advanced analytical and monitoring, and predictive capabilities. This is all done by making one.

Describe how Digital Twin Technology works in a simple way

A digital twin’s life starts with experts in applied math or data science studying the physical and operational data of a real object or system to make a mathematical model that looks like the real thing.

The people who make digital twins make sure that the computer model can get feedback from sensors that get data from the real-world version. This allows the digital replica to emulate and simulate the original in real-time, providing insights about the performance and future issues.

A digital twin can be as complex or simple as you want it to be, with the amount of data used determining how well the model mimics the real-world version.

When a prototype is being made, the twin can help give feedback on how the product is going to work. It can also be used on its own to show what could happen if a physical version was made.

When to use it 

Digital twins are classified into three groups based on their use:

  • Before a physical product is made, this is called a Digital Twin Prototype (DTP).
  • Once a product is made, it is called a Digital Twin Instance (DTI). This is done to run tests on different use cases.
  • Digital Twin Aggregate (DTA) – This gathers DTI information to figure out what a product can do, run prognostics, and test operating parameters, among other things.

These general types can be used for things like logistics planning, product development and re-design, quality control and management, and system planning. Any time that a product or process needs to be tested, a digital twin can be used to cut down on time and money. This can be used in the design, implementation, monitoring, or improvement stages.

Five Real-World Applications of Digital Twins


Manufacturing is one of the primary areas where digital twins are having an impact on how operations are carried out. Automotive manufacturers have adopted digital twin technology to revolutionize the way automobiles are built and assembled. Ford creates seven digital twins for each model of vehicle it manufactures, one for each wheel and tire combination. Each twin is responsible for a distinct component of the manufacturing process, from design through construction and operation. The manufacturing process, production facilities, and the consumer experience are all modeled digitally, as is the customer experience. The digital twin detects energy losses accurately and pinpoints places where energy can be saved and overall manufacturing line performance enhanced.


Digital twins may be used to improve operations in a variety of industries, not just manufacturing. The healthcare industry is also benefiting from the technology. To better prepare for treatments and specific situations in real life, digital twins of patients or their organs are created and made available to healthcare professionals. Sensors the size of bandages are utilized to collect real-time data and feed it into the digital twin to improve health care.


Energy is yet another industry that will profit from digital twins. The wind farm built by General Electric has enhanced production by as much as 20%. In addition, the real-time information given to their digital copies from sensors on each of the turbines allows for more efficient designs and even offers modifications to make each active turbine more effective.


The simulation of real-life events and scenarios in restaurants is assisting the hospitality industry in improving the layout of kitchens and dining spaces to improve people’s movement and customer service. Hotels are also leveraging developing technology to better understand how their guests are using their amenities and to provide more individualized service to each client.


Is it possible to increase the efficiency and processes of an entire city using digital twins? Factory, hotel, and wind farm digital twins have all been shown to improve efficiency and processes. Singapore and Shanghai both have fully functional digital twins that are used to reduce energy use, enhance traffic flow, and even assist in the planning of new developments. Smart cities are quickly becoming a reality, and they offer a wonderful means of reducing pollution and improving the overall well-being of citizens.

Digital twins have a wide range of applications, and they are transforming the way we design, use, and optimize physical places as well as a wide range of processes. With the use of a digital twin, the management of facilities and assets of every imaginable type becomes significantly more efficient. Consider how digital twin technology could be used to improve the efficiency of your own business.

Read More:  How to Put Human Augmentation Technology to Use in the Real World