Digital twin

What is Digital Twin? How it works? & Its Use Cases

Digital twin

What is Digital Twin? How it works? & Its Use Cases

Industry 4.0 has brought exciting changes in various industries. The manufacturing sector is adapting to the principles of industry 4.0 to create more opportunities. The virtual prototypes of the objects reduce the design challenges of the complex machineries.

Digital Twin

It is the virtual representation of a real-world process, product, or system. The virtual replica of real products can be monitored and analysed and to improve performance. Through the integration of the virtual and physical worlds, data can be analysed, and systems can be prevented for downtime, it creates new opportunities to plan using simulations.

Digital Twin integration with Internet of Things (IoT), Artificial Intelligence (AI), Big Data, and software analytics works miraculous. The virtual object can be used to investigate performance, run simulations, and produce potential upgrades to produce insightful data that can be later applied to the original physical device.

How does it work?

The designers of digital Twin make sure that sensors that collect data from the physical world may provide input to the virtual model. With this it is possible to duplicate and simulate what is happening with the original version using the digital version in real time, providing an opportunity to learn more about performance and any potential issues.

The digital twin can be simple or complicated as it needs it to be, and the amount of data used will determine how closely the model resembles the physical object in the real world. The twin can be used alongside a prototype to get feedback as it is being produced or it can function as a prototype unto itself to simulate what might happen when a physical version is constructed.

Types of Digital Twin

Product Twin: It simulates distinct items. Manufacturers often utilize the prototype of a certain product to accesses how it will function in various scenarios and any potential problems. Product Twin can then be utilized to regulate a product’s performance in the real world.

System Twin: They are duplicates of the complete systems. To optimize all operations and maintain the integrity of the system, they gather enormous amounts of operational data generated by the devices and products in the system, obtain insights, and develop new business opportunities.

Process Twin: It is simulating various processes. You can design multiple manufacturing process scenarios in a virtual environment to see what happens in various circumstances. This enables businesses to create the most effective production strategy.

Use cases of Digital Twin


This technology is currently used increasingly in the manufacturing sector. To provide transparent production procedures, complete factories are developed as virtual replicas. Twin assess historical and real-time data to optimize production operations and send out alerts when maintenance work is required. They do this by keeping an eye on the working conditions of machine parts and equipment elements like temperature, rotation rate, humidity, etc. As a result, manufacturers increase production, raise the calibre of their products, and increase their revenue.


It is one such sector that is currently seeing acceleration and innovation. The shift away from retail-based businesses and toward a shipping economy was sped up by the COVID-19 pandemic. Information can be a crucial distinction for businesses trying to advance. Shipping is a complicated operation and using Digital Twin helps businesses identify areas where they may be safer, faster, and more environmentally friendly.


A majority of new automotive development occurs virtually. In the automotive industry, Digital Twin is utilized to build a virtual representation of a linked vehicle. Even before production begins, automobile businesses use technology to build the ultimate product. They simulate and examine both the manufacturing process and potential issues when the vehicle comes to the roads.


At the start of a project, architects design materials which include renderings and models to allow clients to evaluate and approve the design. Communicating design intent during traditional reviews is a difficult process. 2D and 3D models cause details to be lost in translation and renderings aren’t flexible enough to keep everyone on the same page. Digital Twin solve these problems so there are no more costly mistakes.


Nowadays many businesses’ operational processes are undergoing a major transformation. Businesses are experiencing a disruptive digital reinvention for redefining operating models and started developing integrated physical plus digital views of assets, equipment, buildings, and processes. Digital Twin play a pivotal role in this change. It will continue to produce the insights required to improve products and streamline operations to build better products most efficiently.

Sapizon Technologies is a leading company developing Digital Twin solutions for different industries. Visit  Digital Twin at Sapizon for more details.


Let’s work together to make your business journey successful.