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

September 10, 2025
Immersive Technology & AI for Surgical Intelligence – Going Beyond Visualization

Immersive XR Tech and Artificial Intelligence are advancing MedTech beyond cautious incremental change to an era where data-driven intelligence transforms healthcare. This is especially relevant in the operating room — the most complex and high-stakes environment, where precision, advanced skills, and accurate, real-time data are essential. Incremental Change in Healthcare is No Longer an Option Even in a reality transformed by digital medicine, many operating rooms still feel stuck in an analog past, and while everything outside the OR has moved ahead, transformation has been slow and piecemeal inside it. This lag is more pronounced in complex, demanding surgeries, but immersive technologies convert flat, two-dimensional MRI and CT scans into interactive 3D visualizations. Surgeons now have clearer spatial insight as they work, which reduces the risk of unexpected complications and supports better overall results. Yet, healthcare overall has changed only gradually, although progress has been made over the course of decades. Measures such as reducing fraud, rolling out EMR, and updating clinical guidelines have had limited success in controlling costs and closing quality gaps. For example, the U.S. continues to spend more than other similarly developed countries. Everything calls for a fundamental rethinking of how healthcare is structured and delivered. Can our healthcare systems handle 313M+ surgeries a year? Over 313 million surgeries will likely be performed every year by 2030, putting significant pressure on healthcare systems. Longer waiting times, higher rates of complications, and operating rooms stretched to capacity are all on the rise as a result. Against this backdrop, immersive XR and artificial intelligence are rapidly becoming vital partners in the OR. They turn instinct-driven judgement into visual data-informed planning, reducing uncertainty and supporting confident decision-making. The immediate advantages are clear enough: shorter time spent in the operating room include reduced operating-room time and lower radiation exposure for patients, surgeons, and OR staff. Just as critical, though less visible, are the long-term outcomes. Decreased complication rates and a lower likelihood of revision surgeries are likely to have an even greater impact on the future of the field. These issues have catalyzed the rise of startups in surgical intelligence, whose platforms automate parts of the planning process, support documentation, and employ synthetic imaging to reduce time spent in imaging suites. Synthetic imaging, for clarity, refers to digitally generated images, often created from existing medical scans, that enrich diagnostic and interpretive insights. The latest breakthroughs in XR and AI Processing volumetric data with multimodal generative AI, which divides volumes into sequences of patches or slices, now enables real-time interpretation and assistance directly within VR environments. Similarly, VR-augmented differentiable simulations are proving effective for team-based surgical planning, especially for complex cardiac and neurosurgical cases. They integrate optimized trajectory planners with segmented anatomy and immersive navigation interfaces. Organ and whole-body segmentation, now automated and fast, enables multidisciplinary teams to review patient cases together in XR, using familiar platforms such as 3D Slicer. Meanwhile, DICOM-to-XR visualization workflows built on surgical training platforms like Unity and UE5 have become core building blocks to a wave of MedTech startups that proliferated in 2023–2024, with further integrations across the industry. The future of surgery is here The integration of volumetric rendering and AI-enhanced imaging has equipped surgeons with enhanced visualization, helping them navigate the intersection of surgery and human anatomy in 2023. Such progress led to a marked shift in surgical navigation and planning, becoming vital for meeting the pressing demands currently facing healthcare systems. 1) Surgical VR: Volumetric Digital Twins Recent clinical applications of VR platforms convert MRI/CT DICOM stacks into interactive 3D reconstructions of the patient’s body. Surgeons can explore these models in detail, navigate them as if inside the anatomy itself, and then project them as AR overlays into the operative field to preserve spatial context during incision. Volumetric digital twins function as dynamic, clinically vetted, and true-to-size models, unlike static images. They guide trajectory planning, map procedural risks, and enable remote team rehearsals. According to institutions using these tools, the results include clearer surgical approaches, reduced uncertainty around critical vasculature, and greater confidence among both surgeons and patients. These tools serve multidisciplinary physician teams, not only individual users. Everyone involved can review the same digital twin before and during surgery, working in tight synchronization without the risk of mistakes, especially in complex surgeries such as spinal, cranial, or cardiovascular cases. These pipelines also generate high-fidelity, standardized datasets that support subsequent AI integration, as they mature. Automated segmentation, predictive risk scoring, and differentiable trajectory optimizers can now be layered on top, transforming visual intuition into quantifiable guidance and enabling teams to leave less to chance, delivering safer and less invasive care. The VR platform we built for Vizitech USA serves as a strong example within the parallel and broader domain of healthcare education. VMed-Pro is a virtual-reality training platform built to the standards of the National Registry of Emergency Medical Technicians; the scenarios mirror real-world protocols, ensuring that training translates directly to clinical practice. Beyond procedural skills, VMed-Pro also reinforces core medical concepts; learners can review anatomy and physiology within the context of a virtual patient, connecting textbook knowledge to hands-on clinical judgment. 2) Surgical AR: Intra-operative decision making Augmented reality for surgical navigation combines real-time image registration, AI segmentation, ergonomically designed head-worn glasses, and headsets to convert preoperative DICOM stacks into interactive holographic anatomy, giving surgeons X-ray visualization without diverting gaze from the field – a true Surgical Copilot right in the OR. AI-driven segmentation and computer-vision pipelines generate metric-accurate volumetric models and annotated overlays that support trajectory planning, instrument guidance, and intraoperative decision support. Robust spatial registration and tracking (marker-based or depth-sensor aided) align holograms with patient anatomy to submillimetre accuracy, enabling precise tool guidance and reduced reliance on fluoroscopy. Lightweight AR hardware, featuring hand-tracking and voice control, preserves surgeon ergonomics and minimizes distractions. Cloud and on-premises inference options balance latency and computational power to enable real-time assistance. Significant industry investment and agile startups have driven integration with PACS, navigation systems, and multi-user XR sessions, enhancing preoperative rehearsal and team…

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…



Let's discuss your ideas

Contact us