When you hear “digital twins,” you might picture something futuristic — like ABBA’s Voyage concerts, where digital avatars take the stage in place of the band. But digital twins aren’t science fiction. They’re real, practical tools. Businesses use them to monitor systems, test changes, and make smarter decisions with real-world data.
We’ll look at digital twins, how they’re used, and if smaller companies can take advantage of them.
What is a Digital Twin?
A digital twin is a virtual model of a physical object, system, or process. But it’s not just a static 3D replica—it’s dynamic and connected. A digital twin updates in real-time using data from sensors or software, which means it can mirror what’s happening in the physical world, detect changes, and even predict what might happen next.
Think of it like a dashboard that doesn’t just show you what’s happening now. It helps you understand why it’s happening and what’s likely to happen next.
- A digital twin of a building can monitor temperature, energy usage, and air quality.
- A digital twin of a machine can track wear and tear and flag when maintenance is needed.
- A digital twin of a supply chain can model delays, shortages, and cost impacts before they happen.
How are Digital Twins used?
The concept of digital twins isn’t new. NASA was one of the first organizations to use it—long before the term “digital twin” became popular. In the 1970s, NASA built detailed spacecraft simulations during the Apollo program. These helped engineers on the ground monitor systems and respond to issues in real time. These virtual replicas allowed them to test scenarios and troubleshoot problems without needing direct access to the physical spacecraft. It was a groundbreaking approach at the time, and it laid the foundation for today’s digital twin technology.
Digital twins help teams see the full picture. By combining real-time data with a virtual model, they make it easier to understand systems, test changes, and improve performance. Here are some common use cases today:
- Predictive Maintenance: Instead of reacting when equipment fails, companies use digital twins to anticipate issues. This prevents unplanned downtime and reduces repair costs.
- Product Testing and Optimization: Engineers can simulate different scenarios on the digital twin—like stress tests, speed, or heat exposure—before applying those changes in the real world.
- Process Improvement: Businesses can test new workflows or production methods virtually, without the risk or expense of trial-and-error in the real environment.
- Training and Safety: Digital twins offer safe environments for employee training, especially for high-risk systems or equipment.
Are Digital Twins only for Big Enterprises?
Not anymore.
Digital twins began in aerospace, energy, and manufacturing—but today, new tools make them more accessible than ever. Cloud platforms, connected devices, and user-friendly software have lowered the barrier to entry—making digital twins a realistic option even for small businesses.
Here’s what’s changed:
- Sensor and hardware costs are down. Off-the-shelf IoT devices are affordable and easy to install.
- Platforms are more approachable. Cloud services like Azure Digital Twins, Siemens MindSphere, and open-source options allow teams to start small and scale gradually.
- You don’t need a full simulation. You can begin with a single machine, location, or process and expand over time.
How can small businesses get started?
You don’t need a huge team or a big budget to begin. Here’s a simple path:
- Find a clear problem: Look for a process or asset where downtime, inefficiency, or guesswork causes issues. That’s a great candidate for a digital twin.
- Start small: Begin with one machine, space, or workflow. Don’t try to digitize your whole business at once.
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Use existing data: You might already be tracking information in spreadsheets or software tools. Digital twins can often integrate with those systems to create a smarter, more visual view.
- Choose tools that scale: Look for platforms that allow you to grow into more complexity, not ones that require it from the start.
Digital Twins in Action
Digital twins offer a powerful way to visualize, test, and improve the systems that power your business. They’re no longer limited to large enterprises or high-tech sectors. With the right approach, small businesses can use digital twins to reduce downtime, improve operations, and make smarter decisions—all with fewer surprises along the way.
If you want to understand how your systems work—or why they’re not—a digital twin is a good place to start.