What is Digital Twin? An Overview of Meaning and Potential of this Technology
What is Digital Twin? An Overview of Meaning and Potential of this Technology

A digital twin is a 3D model that recreates the main traits of a physical object. The main essence of digital twin technology is the data collected from trackers on the real object and transferred to cloud storage. The data updates in real-time. Digital twins of physical objects can be reproduced in virtual reality or be superimposed on a real environment like an AR object.

Usually, digital twins can recreate buildings, people, constructions, and the whole interaction mechanism like chain supply. And one of the main purposes of implementing virtual twins is to model object potential behavior, as well as to fix construction mistakes in the early stages of development.

Today, this technology is successfully implemented by various famous companies, including Renault, Karcher, Amazon, etc. In 2021, according to Allied Market Research, the digital twins market was estimated at 6,5 USD billion, and by 2030 this market value will have increased to more than 125 USD billion. 

So, in this article, we will give more information about digital twins and in which business fields this technology is applied.

How Digital Twins Are Created

Digital twins are developed using ІоТ trackers, cameras, and business apps, that collect the necessary real object data to recreate its digital version.

The cloud platform AWS IoT TwinMaker від Amazon is one of the programs to develop digital twins. This platform facilitates and accelerates the digital twin-building process for many industries like construction, logistics, manufacturing, and others. On the platform, you can develop 3D twins of buildings, manufacturing equipment, and chain supplies.

Advantages of Digital Twins

Some of  the main advantages of implementing digital twins in the business include

  • Digital twins help to make an important decision on creating real objects. James Taylor, Forbes Business Member and CEO of Decision Management Solutions, in his article Digital Twins: The Solution To Better Decision-Making describes how digital twins can facilitate making decisions and help to predict all possible risks. 

What is digital twins

  • Digital twins offer real-time tracking of the working process. And in some fields, like manufacturing, for example, digital twins tracking can be even life-saving.

“With real-time replication of the physical status of assets — walk-in freezers, refrigerators, promotional coolers, shelving, carts, and other equipment — and automated corrective actions, it’s easier to avoid wasting electricity, time, and product when anomalies arise. Digital twins promote positive outcomes for asset protection programs through reduced waste and loss and, most importantly, saved lives,” wrote Guy Yehiav, President of SmartSense. 

  • Digital twins offer an option to predict how the real object could work in different circumstances. According to Business Wire Report, 75% of Air Force executives are confident in applying digital twins. When using this technology, engineers can be assured of the safety of people on airplane boards. With the help of digital data, they can predict possible issues in aircraft and their engines, etc. 

Limitations and Challenges of Digital Twinning

With the development of digital twins, you should pay attention to such challenges as

  • Difficulties with the search for necessary data to design certain digital twins. “Sometimes the data is owned by private companies. Occasionally the federal level holds the data. Often, there is no real-time data available or only from a limited amount of sensors, and at times there is no data at all,” said Marco van Bemmel, web developer and author of the article “Three Key Challenges Towards Digital Twin Adoption at Scale”.
  • At the same time, you should consider proper digital data security from leaks. According to Gartner, in 2023, almost 75% of digital twins of original equipment manufacturers connected to ІоТ will use, at least, five different types of integration endpoints — network addresses in the Cloud with integration data. And, every type of address has its own insecurities to consider, so there is a need for constant security protocol updates. 

Examples of Digital Twins In Action

How Digital Twin Technology is Transforming the Automotive Industry

Digital twins in the automotive industry are usually applied for designing 3D copies of cars. Particularly, with digital twins, you can calculate a car’s behavior on a road and eliminate construction mistakes.

For example, French automotive company Renault is already implementing digital twins for new vehicle development, including design and construction. 

“With their three-dimensional digital simulation tools, engineers can even place a virtual occupant inside the future vehicle early in the process, just as they would in a physical car. These tests help assess certain constraints, such as positioning (ergonomics) and HMI (human-machine interface),” wrote Nicola Le-Boucher, author of the article Vehicle Digital Twin: when physical and digital models unite для Renault Group

Digital Twins Use Cases in Healthcare

In healthcare, digital twins are applied for recreating patients’ bodies, based on their physical condition and medical history. The data changes in real-time and shows a patient’s current well-being and the progress of the disease. 

A digital twin of human creation is a more difficult and sophisticated process. That’s because doctors use blood tests, X-ray pictures, and other analyses to create a patient’s digital copy, trying to preserve all their individual physical characteristics as realistically as possible.

Doctors use digital twins of patients for different purposes: medicine testing and surgery simulations. By the way, doctors in Brazil used digital copies of conjoined twins to do a 28-hour-long surgery to separate patients. You can read more about it here

Speaking about medicine testing, doctors from Linköping University in Sweden use digital twins for choosing the right treatment for patients. For example, scientists started building digital twins of mice, based on their RNA.

“Our aim is to develop those models into ‘digital twins’ of individual patients’ diseases in order to tailor medication to each patient, said doctor Mikael Benson, a professor at the university who led the study. Ideally, each twin will be computationally matched with and treated with thousands of drugs, before actually selecting the best drug to treat the patient”. 

How Digital Twin Technology is Revolutionizing Construction

In construction, digital twins help not only to project and construct new buildings quickly and efficiently but also track the current condition of already existing ones.

Digital twins of buildings in augmented reality are already proven to be efficient at designing buildings, rooms, and landscapes

Speaking about already existing constructions, German company ВАМ and Dutch company TNO collaborated to develop digital twins for infrastructure objects, like bridges. Every building has trackers that collect the object condition data. The data helps to find out whether the object needs repairing. The bridge trackers, for example, collect data from vibrations caused by vehicles driving over the bridge. The data is transferred to a computer through a cable, conducted along the bridge.

Future of Logistics: Supply Chain Digital Twins Explained

In logistics, digital twins offer a possibility to calculate the right product delivery routes, consider alternative chain supplies and the amount of safety stock.

When the COVID-19 pandemic started and disrupted supply chains, Microsoft, together with Coupa, had to use data for developing digital twins to consider the optimal supply chain.

“Data is the key, and I have a philosophy of managing your business by facts and figures, said Jonathan Allen, director of global network modeling, design, and planning at Microsoft. It’s about how we take our physical supply chain and digitize it in a way that you have a digital mapping and duplication of what’s happening physically across the supply chain.” 

Digital Twins: Future of Manufacturing Industry

Digital twins technology in manufacturing offers you to model a final product and eliminate potential defects in the early stages. For example, Karcher applied digital twin technology to improve the quality of batteries. Their main purpose for using digital twins was to reduce the size and heating of the batteries.

 

In general, digital twin technology is an interesting and efficient way to transform modern business fields. Using the technology, you can optimize factories’ work, improve the design of  the product, and track the condition of already existing constructions. Moreover, digital twins become popular in healthcare, since sophisticated virtual copies of patients help doctors test medicine and choose the right treatment without causing harm to real people. Above, we offer only a short list of industries, where digital twins are successfully applied.

Image: Freepik

Latest Articles

June 27, 2025
Methodology of VR/MR/AR and AI Project Estimation

Estimation of IT projects based on VR, XR, MR, or AI requires both a deep technical understanding of advanced technologies and the ability to predict future market tendencies, potential risks, and opportunities. In this document, we aim to thoroughly examine estimation methodologies that allow for the most accurate prediction of project results in such innovative fields as VR/MR/AR and AI by describing unique approaches and strategies developed by Qualium Systems. We strive to cover existing estimation techniques used at our company and delve into the strategies and approaches that ensure high efficiency and accuracy of the estimation process. While focusing on different estimation types, we analyze the choice of methods and alternative approaches available. Due attention is paid to risk assessment being the key element of a successful IT project implementation, especially in such innovative fields as VR/MR/AR and AI. Moreover, the last chapter covers the demo of a project of ours, the Chemistry education app. We will show how the given approaches practically affect the final project estimation. Read

June 27, 2025
What Are Spatial Anchors and Why They Matter

Breaking Down Spatial Anchors in AR/MR Augmented Reality (AR) and Mixed Reality (MR) depend on accurate understanding of the physical environment to create realistic experiences, and they hit this target with the concept of spatial anchors. These anchors act like markers, either geometric or based on features, that help virtual objects stay in the same spot in the real world — even when users move around. Sounds simple, but the way spatial anchors are implemented varies a lot depending on the platform; for example, Apple’s ARKit, Google’s ARCore, and Microsoft’s Azure Spatial Anchors (ASA) all approach them differently. If you want to know how these anchors are used in practical scenarios or what challenges developers often face when working with them, this article dives into these insights too. What Are Spatial Anchors and Why They Matter A spatial anchor is like a marker in the real world, tied to a specific point or group of features. Once you create one, it allows for some important capabilities: Persistence. Virtual objects stay exactly where you placed them in the real-world, even if you close and restart the app. Multi-user synchronization. Multiple devices can share the same anchor, so everyone sees virtual objects aligned to the same physical space. Cross-session continuity. You can leave a space and come back later, and all the virtual elements will still be in the right place. In AR/MR, your device builds a point cloud or feature map by using the camera and built-in sensors like the IMU (inertial measurement unit). Spatial anchors are then tied to those features, and without them, virtual objects can drift or float around as you move, shattering the sense of immersion. Technical Mechanics of Spatial Anchors At a high level, creating and using spatial anchors involves a series of steps: Feature Detection & Mapping To start, the device needs to understand its surroundings: it scans the environment to identify stable visual features (e.g., corners, edges). Over time, these features are triangulated, forming a sparse map or mesh of the space. This feature map is what the system relies on to anchor virtual objects. Anchor Creation Next, anchors are placed at specific 3D locations in the environment in two possible ways: Hit-testing. The system casts a virtual ray from a camera to a user-tapped point, then drops an anchor on the detected surface. Manual placement. Sometimes, developers need precise control, so they manually specify the exact location of an anchor using known coordinates, like ensuring it perfectly fits on the floor or another predefined plane. Persistence & Serialization Anchors aren’t temporary — they can persist, and here’s how systems make that possible: Locally stored anchors. Frameworks save the anchor’s data, like feature descriptors and transforms, in a package called a “world map” or “anchor payload”. Cloud-based anchors. Cloud services like Azure Spatial Anchors (ASA) upload this anchor data to a remote server to let the same anchor be accessed across multiple devices. Synchronization & Restoration When you’re reopening the app or accessing the anchor on a different device, the system uses the saved data to restore the anchor’s location. It compares stored feature descriptors to what the camera sees in real time, and if there’s a good enough match, the system confidently snaps the anchor into position, and your virtual content shows up right where it’s supposed to. However, using spatial anchors isn’t perfect, like using any other technology, and there are some tricky issues to figure out: Low latency. Matching saved data to real-time visuals has to be quick; otherwise, the user experience feels clunky. Robustness in feature-scarce environments. Blank walls or textureless areas don’t give the system much to work with and make tracking tougher. Scale drift. Little errors in the system’s tracking add up over time to big discrepancies. When everything falls into place and the challenges are handled well, spatial anchors make augmented and virtual reality experiences feel seamless and truly real. ARKit’s Spatial Anchors (Apple) Apple’s ARKit, rolled out with iOS 11, brought powerful features to developers working on AR apps, and one of them is spatial anchoring, which allows virtual objects to stay fixed in the real world as if they belong there. To do this, ARKit provides two main APIs that developers rely on to achieve anchor-based persistence. ARAnchor & ARPlaneAnchor The simplest kind of anchor in ARKit is the ARAnchor, which represents a single 3D point in the real-world environment and acts as a kind of “pin” in space that ARKit can track. Building on this, ARPlaneAnchor identifies flat surfaces like tables, floors, and walls, allowing developers to tie virtual objects to these surfaces. ARWorldMap ARWorldMap makes ARKit robust for persistence and acts as a snapshot of the environment being tracked by ARKit. It captures the current session, including all detected anchors and their surrounding feature points, into a compact file. There are a few constraints developers need to keep in mind: World maps are iOS-only, which means they cannot be shared directly with Android. There must be enough overlapping features between the saved environment and the current physical space, and textured structures are especially valuable for this, as they help ARKit identify key points for alignment. Large world maps, especially those with many anchors or detailed environments, can be slow to serialize and deserialize, causing higher application latency when loading or saving. ARKit anchors are ideal for single-user persistence, but sharing AR experiences across multiple devices poses additional issues, and developers often employ custom server logic (uploading ARWorldMap data to a backend), enabling users to download and use the same map. However, this approach comes with caveats: it requires extra development work and doesn’t offer native support for sharing across platforms like iOS and Android. ARCore’s Spatial Anchors (Google) Google’s ARCore is a solid toolkit for building AR apps, and one of its best features is how it handles spatial anchors: Anchors & Hit-Testing ARCore offers two ways to create anchors. You can use Session.createAnchor(Pose) if you already know the anchor’s position, or…

June 2, 2025
Extended Reality in Industry 4.0: Transforming Industrial Processes

Understanding XR in Industry 4.0 Industry 4.0 marks a turning point in making industry systems smarter and more interconnected: it integrates digital and physical technologies like IoT, automation, and AI, into them. And you’ve probably heard about Extended Reality (XR), the umbrella for Virtual Reality, Augmented Reality, and Mixed Reality. It isn’t an add-on. XR is one of the primary technologies making the industry system change possible. XR has made a huge splash in Industry 4.0, and recent research shows how impactful it has become. For example, a 2023 study by Gattullo et al. points out that AR and VR are becoming a must-have in industrial settings. It makes sense — they improve productivity and enhance human-machine interactions (Gattullo et al., 2023). Meanwhile, research by Azuma et al. (2024) focuses on how XR makes workspaces safer and training more effective in industrial environments. One thing is clear: the integration of XR into Industry 4.0 closes the gap between what we imagine in digital simulations and what actually happens in the real world. Companies use XR to work smarter — it tightens up workflows, streamlines training, and improves safety measures. The uniqueness of XR is in its immersive nature. It allows teams to make better decisions, monitor operations with pinpoint accuracy, and effectively collaborate, even if team members are on opposite sides of the planet. XR Applications in Key Industrial Sectors Manufacturing and Production One of the most significant uses of XR in Industry 4.0 is in manufacturing, where it enhances design, production, and quality control processes. Engineers now utilize digital twins, virtual prototypes, and AR-assisted assembly lines, to catch possible defects before production even starts. Research by Mourtzis et al. (2024) shows how effective digital twin models powered by XR are in smart factories: for example, studies reveal that adopting XR-driven digital twins saves design cycle times by up to 40% and greatly speeds up product development. Besides, real-time monitoring with these tools has decreased system downtimes by 25% (Mourtzis et al., 2024). Training and Workforce Development The use of XR in employee training has changed how industrial workers acquire knowledge and grow skills. Hands-on XR-based simulations allow them to practice in realistic settings without any of the risks tied to operating heavy machinery, whereas traditional training methods usually involve lengthy hours, high expenses, and the need to set aside physical equipment, disrupting operations. A study published on ResearchGate titled ‘Immersive Virtual Reality Training in Industrial Settings: Effects on Memory Retention and Learning Outcomes’ offers interesting insights on XR’s use in workforce training. It was carried out by Jan Kubr, Alena Lochmannova, and Petr Horejsi, researchers from the University of West Bohemia in Pilsen, Czech Republic, specializing in industrial engineering and public health. The study focused on fire suppression training to show how different levels of immersion in VR affect training for industrial safety procedures. The findings were astounding. People trained in VR remembered 45% more information compared to those who went through traditional training. VR also led to a 35% jump in task accuracy and cut real-world errors by 50%. On top of that, companies using VR in their training programs noticed that new employees reached full productivity 25% faster. The study uncovered a key insight: while high-immersion VR training improves short-term memory retention and operational efficiency, excessive immersion — for example, using both audio navigation and visual cues at the same time — can overwhelm learners and hurt their ability to absorb information. These results showed how important it is to find the right balance when creating VR training programs to ensure they’re truly effective. XR-based simulations let industrial workers safely engage in realistic and hands-on scenarios without the hazards or costs of operating heavy machinery, changing the way they acquire new skills. Way better than sluggish, costly, and time-consuming traditional training methods that require physical equipment and significant downtime. Maintenance and Remote Assistance XR is also transforming equipment maintenance and troubleshooting. In place of physical manuals, technicians using AR-powered smart glasses can view real-time schematics, follow guided diagnostics, and connect with remote experts, reducing downtime. Recent research by Javier Gonzalez-Argote highlights how significantly AR-assisted maintenance has grown in the automotive industry. The study finds that AR, mostly mediated via portable devices, is widely used in maintenance, evaluation, diagnosis, repair, and inspection processes, improving work performance, productivity, and efficiency. AR-based guidance in product assembly and disassembly has also been found to boost task performance by up to 30%, substantially improving accuracy and lowering human errors. These advancements are streamlining industrial maintenance workflows, reducing downtime and increasing operational efficiency across the board (González-Argote et al., 2024). Industrial IMMERSIVE 2025: Advancing XR in Industry 4.0 At the Industrial IMMERSIVE Week 2025, top industry leaders came together to discuss the latest breakthroughs in XR technology for industrial use. One of the main topics of discussion was XR’s growing impact on workplace safety and immersive training environments. During the event, Kevin O’Donovan, a prominent technology evangelist and co-chair of the Industrial Metaverse & Digital Twin committee at VRARA, interviewed Annie Eaton, a trailblazing XR developer and CEO of Futurus. She shared exciting details about a groundbreaking safety training initiative, saying: “We have created a solution called XR Industrial, which has a collection of safety-themed lessons in VR … anything from hazards identification, like slips, trips, and falls, to pedestrian safety and interaction with mobile work equipment like forklifts or even autonomous vehicles in a manufacturing site.” By letting workers practice handling high-risk scenarios in a risk-free virtual setting, this initiative shows how XR makes workplaces safer. No wonder more companies are beginning to see the value in using such simulations to improve safety across operations and avoid accidents. Rethinking how manufacturing, training, and maintenance are done, extended reality is rapidly becoming necessary for Industry 4.0. The combination of rising academic study and practical experiences, like those shared during Industrial IMMERSIVE 2025, highlights how really strong this technology is. XR will always play a big role in optimizing efficiency, protecting workers, and…



Let's discuss your ideas

Contact us