What Are Digital Twins and Why Should You Care?

A Digital Twin is a virtual model (or replica) of a real-world object, system, or process. It’s not just a static 3D model—it is a living, data-driven mirror of its physical counterpart that updates in real time.

Think of it as a “bridge” between the physical and digital world.

How a Digital Twin works?

• Physical Asset with Sensors & IoT Devices

  • The real-world asset (machine, building, vehicle, etc.) is equipped with sensors and IoT devices.

  • These devices continuously collect operational data such as temperature, vibration, energy consumption, and environmental conditions.

• Data Transmission

  • The gathered data is sent to processing units via networks (5G, Wi-Fi, LoRaWAN, etc.).

• Edge Processing (Near the Asset)

  • Before transmission to the cloud, the raw data is cleaned, filtered, and pre-processed at the edge (closer to the asset).

  • This reduces noise, saves bandwidth, and ensures faster response.

• Cloud Storage & Management

  • Processed data is stored in cloud platforms or data lakes.

  • Both historical records and real-time streams are maintained for analysis.

• Creation of the Virtual Model (The Digital Twin)

  • A virtual replica of the asset is developed using:

    • CAD (Computer-Aided Design) for geometry and structure.

    • BIM (Building Information Modelling) for infrastructure and buildings.

    • Physics-based models + AI/ML for behaviour and performance.

• Analysis & Simulation

  • The digital twin is used for

    • Monitoring: Real-time performance tracking.

    • Simulation: Testing “what-if” scenarios virtually.

    • Prediction: Forecasting failures or performance issues with AI.

    • Optimisation: Suggesting or automating adjustments to improve efficiency.

      
      

      This process creates a feedback loop: The insights from the digital twin are sent back to the physical asset, enabling smarter operations, predictive maintenance, and continuous optimisation.

      
      

  Physical Asset → Data → Cloud → Virtual Twin → Analysis → Feedback

  

  Work flow of Digital twinning

  Advantages of Digital Twins:

• Real-Time Monitoring

• Predictive Maintenance

• Cost Savings

• Improved Design & Development

•  Better Decision-Making

• Operational Efficiency

• Enhanced Customer Experience

•  Risk Reduction

•  Sustainability & Energy Efficiency

• Life-cycle Management

  
  

  Digital twins reduce costs, enhance safety, maximise efficiency, and empower smarter decision-making — all while driving innovation and supporting sustainability.

Conclusion

Digital Twins are transforming the way we understand and manage the physical world. By creating a real-time digital replica of assets and processes, they allow businesses and cities to monitor, simulate, and predict outcomes more effectively. From reducing downtime in factories to improving energy efficiency in smart cities, the possibilities are endless.

As technology advances, Digital Twins will play an even bigger role in building a smarter, safer, and more efficient future